System for assembling a cartridge for a smoking article and associated method

ABSTRACT

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by coupling a base of the cartridge to a carriage that is transported via a track. The track transports the carriages between various substations at which one or more parts are added to the base. The carriage may be lifted from the track by a lifter mechanism at each substation in order to perform assembly operations on the base. An inspection system may inspect the cartridges at various stages of completion at or between the various substations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/716,112, filed May 19, 2015, which application is hereby incorporatedby reference in its entirety in this application.

BACKGROUND Field of the Disclosure

The present disclosure relates to a cartridge for aerosol deliverydevices such as electronic cigarettes, and more particularly to methodsfor assembling a cartridge for aerosol delivery devices including anatomizer, and associated systems and apparatuses. The atomizer may beconfigured to heat an aerosol precursor, which may be made or derivedfrom tobacco or otherwise incorporate tobacco, to form an inhalablesubstance for human consumption.

Description of Related Art

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 8,881,737 to Collett et al., U.S. Pat. App. Pub. No.2013/0255702 to Griffith Jr. et al., U.S. Pat. App. Pub. No.2014/0000638 to Sebastian et al., U.S. Pat. App. Pub. No. 2014/0096781to Sears et al., U.S. Pat. App. Pub. No. 2014/0096782 to Ampolini etal., and U.S. patent application Ser. No. 14/011,992 to Davis et al.,filed Aug. 28, 2013, which are incorporated herein by reference in theirentireties. See also, for example, the various embodiments of productsand heating configurations described in the background sections of U.S.Pat. No. 5,388,594 to Counts et al. and U.S. Pat. No. 8,079,371 toRobinson et. al, which are incorporated by reference in theirentireties.

However, some electronic smoking articles or portions thereof may bedifficult to manufacture. In this regard, for example, the variouscomponents of electronic smoking articles may be relatively small and/orfragile. Thus, advances with respect to systems, apparatuses, andmethods for manufacturing electronic smoking articles would bedesirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to assembly of cartridges for aerosoldelivery devices configured to produce aerosol and which aerosoldelivery devices, in some embodiments, may be referred to as electroniccigarettes. In one aspect, an assembly substation is provided. Theassembly substation may include a supply unit configured to provide aplurality of components, a first assembly unit configured to receive afirst portion of the components, and a second assembly unit configuredto receive a second portion of the components. The first assembly unitand the second assembly unit may be respectively configured to assemblethe first portion of the components and the second portion of componentsinto a plurality of cartridges for an aerosol delivery device. Theassembly substation may additionally include a feeder unit configured toreceive the components from the supply unit and alternatingly feed thefirst portion of the components to the first assembly unit and feed thesecond portion of the components to the second assembly unit.

In some embodiments the feeder unit may include a rotary memberconfigured to swivel between a first delivery position in which therotary member is configured to deliver the first portion of thecomponents to the first assembly unit and a second delivery position inwhich the rotary member is configured to deliver the second portion ofthe components to the second assembly unit. The rotary member mayinclude a first engagement head and a second engagement headrespectively configured to receive one of the components from the supplyunit. The first engagement head may be configured to receive one of thecomponents from the supply unit while the second engagement head feedsone of the components to the second assembly unit. The second engagementhead may be configured to receive one of the components from the supplyunit while the first engagement head feeds one of the components to thefirst assembly unit.

In some embodiments the supply unit may include a vibratory arrangementdefining a pathway configured to arrange the components in aserially-aligned stream and a singulator configured to singulate thecomponents from the serially-aligned stream. The supply unit may furtherinclude an actuator configured to individually remove the componentsfrom the serially-aligned stream or realign the components whenmisaligned in a first direction. The pathway may define a gap configuredto remove the components from the serially-aligned stream when thecomponents are misaligned in a second direction.

In an additional aspect, an assembly method is provided. The assemblymethod may include providing a plurality of components via a supplyunit, alternatingly feeding a first portion of the components from thesupply unit to a first assembly unit and a second portion of thecomponents to a second assembly unit, and assembling the first portionof the components with the first assembly unit and the second portion ofthe components with the second assembly unit into a plurality ofcartridges for an aerosol delivery device.

In some embodiments, alternatingly feeding the first portion of thecomponents from the supply unit to the first assembly unit and thesecond portion of the components to the second assembly unit may includeswiveling a rotary member between a first delivery position in which therotary member is configured to deliver the first portion of thecomponents to the first assembly unit and a second delivery position inwhich the rotary member is configured to deliver the second portion ofthe components to the second assembly unit. Swiveling the rotary membermay include receiving one of the components from the supply unit in afirst engagement head while a second engagement head feeds one of thecomponents to the second assembly unit and receiving one of thecomponents from the supply unit in the second engagement head while thefirst engagement head feeds one of the components to the first assemblyunit.

In some embodiments providing the components via the supply unit mayinclude directing the components along a pathway in a serially-alignedstream and singulating the components from the serially-aligned stream.The method may additionally include individually removing the componentsfrom the serially-aligned stream or realigning the components whenmisaligned in a first direction. The method may further include removingthe components from the serially-aligned stream through a gap in thepathway when the components are misaligned in a second direction.

In an additional aspect, a system configured to assemble a plurality ofcartridges for an aerosol delivery device is provided. The system mayinclude a plurality of assembly substations collectively configured toassemble a base and a plurality of additional components together. Thebase may extend between an inner end configured to receive theadditional components during assembly of the cartridges and anattachment end defining an internal surface configured to engage acontrol body during usage of the aerosol delivery device. The system mayfurther include a track extending between the assembly substations.Additionally, the system may include a carriage configured to engage thetrack and to cooperate therewith to move between the assemblysubstations. The carriage may include an engagement head defining aplurality of sections configured to engage the internal surface of theattachment end of the base via an interference fit to provide theassembly substations with access to the inner end of the base to attachthe additional components thereto.

In some embodiments the assembly substations may include a base loadsubstation. The base load substation may be configured to rotationallyalign the base with the engagement head of the carriage and engage thebase with the engagement head. The base load substation may include animaging device configured to detect a rotational orientation of the basebased on image of the attachment end of the base. The carriage mayinclude a storage module configured to store cartridge identificationand status information.

In some embodiments the carriage may define one or more alignmentapertures and the track may include one or more locking pins configuredto engage the alignment apertures to releasably lock the carriage at oneor more of the assembly substations.

The track further may further include a conveyor and a lifter mechanism.The lifter mechanism may include the locking pins and may be configuredto lift the carriage from the conveyor. The carriage may include anelectrostatic dissipative material. The carriage may further include alocator module including a ferromagnetic material.

In an additional aspect, an assembly method is provided. The assemblymethod may include providing a base and a plurality of additionalcomponents collectively configured to form a plurality of cartridges foran aerosol delivery device. The base may extend between an inner endconfigured to receive the additional components during assembly of thecartridges and an attachment end defining an internal surface configuredto engage a control body during usage of the aerosol delivery device.The method may further include providing a plurality of assemblysubstations, a track, and a carriage comprising an engagement headdefining a plurality of sections. The track may extend between theassembly substations, and the carriage may be configured to engage thetrack and to cooperate therewith to move between the assemblysubstations. The method may additionally include engaging the internalsurface of the attachment end of the base with the sections of theengagement head via an interference fit to provide the assemblysubstations with access to the inner end of the base. Further, themethod may include transporting the carriage by way of the track betweenthe assembly substations and assembling the additional components withthe inner end of the base at the assembly substations.

In some embodiments, engaging the base with the engagement head mayinclude rotationally aligning the base with the engagement head.Rotationally aligning the base with the engagement head may includedetecting a rotational orientation of the base based on image of theattachment end of the base. Further, the method may include storingcartridge identification and status information in a storage modulecoupled to the carriage. The method may also include locking thecarriage at one or more of the substations by directing one or morelocking pins from the track into one or more alignment apertures definedin the carriage. Transporting the carriage by way of the track mayinclude transporting the carriage by way of a conveyor, and whereinlocking the carriage comprises lifting the carriage from the conveyor.

In a further, aspect, an assembly substation is provided. The assemblysubstation may include a robotic arm configured to insert apartially-assembled cartridge into an outer body. Thepartially-assembled cartridge may include a base, a negative heatingterminal, a positive heating terminal, a heating element, and a liquidtransport element. The negative heating terminal and the positiveheating terminal may be coupled to the base. The heating element may becoupled to the negative heating terminal and the positive heatingterminal. The robotic arm may include an outer body gripper configuredto receive an outer body therein. The robotic arm may be configured todirect the outer body gripper with the outer body positioned thereinover the partially-assembled cartridge such that at least a portion ofthe negative heating terminal, the positive heating terminal, theheating element, and the liquid transport element are received in theouter body. The assembly substation may additionally include a suctionsystem operably engaged with the outer body gripper of the robotic arm.The outer body gripper may be configured to apply a negative pressuresupplied by the suction system longitudinally through the outer body tofacilitate insertion of the partially-assembled cartridge into the outerbody.

In some embodiments the assembly substation may additionally include abending mechanism configured to receive the partially-assembledcartridge therein so as to bend the liquid transport element against thenegative heating terminal and the positive heating terminal. Theassembly substation may also include a substrate gripper configured towrap a reservoir substrate at least partially around the bendingmechanism, The bending mechanism may be configured to retract relativeto the partially-assembled cartridge following wrapping of the reservoirsubstrate such that the reservoir substrate is wrapped at leastpartially about the negative heating terminal and the positive heatingterminal and in contact with the liquid transport element.

In some embodiments the outer body gripper may include a piston. Thepiston may be in fluid communication with the suction system andconfigured to engage an end of the outer body to apply the negativepressure through the outer body. The piston may be configured to pressthe outer body into engagement with the base. The outer body gripper maybe configured to receive the outer body therein while the bendingmechanism receives the partially-assembled cartridge therein.

In an additional aspect, an assembly method is provided. The assemblymethod may include providing a partially-assembled cartridge including abase, a negative heating terminal, a positive heating terminal, aheating element, and a liquid transport element. The negative heatingterminal and the positive heating terminal may be coupled to the base.The heating element may be coupled to the negative heating terminal andthe positive heating terminal. The assembly method may additionallyinclude inserting the partially-assembled cartridge within an outer bodyby engaging the outer body with an outer body gripper of a robotic armand directing the outer body over the partially-assembled cartridge.Further, the method may include applying a negative pressure to theouter body supplied by a suction system operably engaged with the outerbody gripper of the robotic arm to facilitate insertion of thepartially-assembled cartridge into the outer body.

In some embodiments, the assembly method may further include insertingthe partially-assembled cartridge in a bending mechanism to bend theliquid transport element against the negative heating terminal and thepositive heating terminal. The assembly method may also include wrappinga reservoir substrate at least partially around the bending mechanism.Further, the assembly method may include retracting the bendingmechanism relative to the partially-assembled cartridge followingwrapping of the reservoir substrate such that the reservoir substrate iswrapped at least partially about the negative heating terminal and thepositive heating terminal and in contact with the liquid transportelement.

In some embodiments, applying the negative pressure to the outer bodymay include engaging an end of the outer body with a piston of the outerbody gripper. The piston may be in fluid communication with the suctionsystem and configured to apply the negative pressure through the outerbody. The assembly method may additionally include pressing the outerbody into engagement with the base with the piston.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates an aerosol delivery device comprising a cartridge anda control body, the cartridge being illustrated in an explodedconfiguration and the control body being illustrated in an assembledconfiguration according to an example embodiment of the presentdisclosure;

FIG. 2 illustrates the control body of FIG. 1 in an explodedconfiguration according to an example embodiment of the presentdisclosure;

FIG. 3 schematically illustrates a system for producing cartridges foran aerosol delivery device including a cartridge assembly subsystem, acartridge filling subsystem, a cartridge capping subsystem, a cartridgelabeling subsystem, and an inspection subsystem according to an exampleembodiment of the present disclosure;

FIG. 4 schematically illustrates the cartridge assembly subsystem ofFIG. 3 according to an example embodiment of the present disclosure;

FIG. 5 illustrates a top perspective view of a carriage of the cartridgeassembly subsystem of FIG. 4 according to an example embodiment of thepresent disclosure;

FIG. 6 illustrates a bottom perspective view of the carriage of FIG. 5according to an example embodiment of the present disclosure;

FIG. 7 illustrates a side view of the carriage of FIG. 5 with basesengaged with first and second engagement heads thereof according to anexample embodiment of the present disclosure;

FIG. 8 illustrates a perspective view of a base load substation of thecartridge assembly subsystem of FIG. 4 according to an exampleembodiment of the present disclosure;

FIG. 9 illustrates an enlarged view of a supply unit of the base loadsubstation of FIG. 8 according to an example embodiment of the presentdisclosure;

FIG. 10 illustrates an enlarged view of a singulator of the supply unitof FIG. 9 according to an example embodiment of the present disclosure;

FIG. 11 illustrates an enlarged perspective view of a feeder unit of thebase load substation of FIG. 8 according to an example embodiment of thepresent disclosure;

FIG. 12 illustrates an alternate enlarged perspective view of the feederunit of the base load substation of FIG. 8 according to an exampleembodiment of the present disclosure;

FIG. 13 illustrates a first assembly unit and a second assembly unit ofthe base load substation of FIG. 8 according to an example embodiment ofthe present disclosure;

FIG. 14 illustrates an enlarged view of a base of the cartridge of FIG.1 in a desired rotational orientation relative to a machine directionaccording to an example embodiment of the present disclosure;

FIG. 15 illustrates a view of a track of the cartridge assemblysubsystem of FIG. 4 proximate the base load substation of FIG. 8according to an example embodiment of the present disclosure;

FIG. 16 illustrates an opposing view of the track of the cartridgeassembly subsystem of FIG. 4 proximate the base load substation of FIG.8 according to an example embodiment of the present disclosure;

FIG. 17 illustrates a perspective view of a control component terminalcoupling substation of the cartridge assembly substation of FIG. 4according to an example embodiment of the present disclosure;

FIG. 18 illustrates an enlarged view of a supply unit of the controlcomponent terminal coupling substation of FIG. 17 according to anexample embodiment of the present disclosure;

FIG. 19 illustrates an enlarged view of a pathway defined by a vibratorybowl of the supply unit of FIG. 18 according to an example embodiment ofthe present disclosure;

FIG. 20 illustrates a view of a singulator of the supply unit of FIG. 18according to an example embodiment of the present disclosure:

FIG. 21 illustrates an enlarged view of the singulator of FIG. 20 with asingulated control component terminal according to an example embodimentof the present disclosure;

FIG. 22 illustrates a first assembly unit and a second assembly unit ofthe control component terminal coupling substation of FIG. 17 accordingto an example embodiment of the present disclosure;

FIG. 23 illustrates an enlarged view of a first engagement head of thefirst assembly unit of FIG. 22 according to an example embodiment of thepresent disclosure;

FIG. 24 illustrates a perspective view of the track of the cartridgeassembly subsystem of FIG. 4 proximate the control component couplingsubstation according to an example embodiment of the present disclosure;

FIG. 25 illustrates a perspective view of bases of the cartridge of FIG.1 with a control component terminal partially engaged therewithaccording to an example embodiment of the present disclosure:

FIG. 26 illustrates a press of the control component coupling substationof FIG. 17 according to an example embodiment of the present disclosure;

FIG. 27 illustrates a perspective view of a negative heating terminalcoupling substation of the cartridge assembly substation of FIG. 4according to an example embodiment of the present disclosure;

FIG. 28 illustrates an enlarged view of a supply unit of the negativeheating terminal coupling substation of FIG. 17 according to an exampleembodiment of the present disclosure;

FIG. 29 illustrates an enlarged view of a singulator of the supply unitof FIG. 28 according to an example embodiment of the present disclosure;

FIG. 30 illustrates an enlarged view of a feeder unit of the negativeheating terminal coupling substation of FIG. 17 according to an exampleembodiment of the present disclosure;

FIG. 31 illustrates a first assembly unit and a second assembly unit ofthe negative heating terminal coupling substation of FIG. 27 accordingto an example embodiment of the present disclosure;

FIG. 32 illustrates an enlarged view of an end effector of the firstassembly unit of FIG. 31 according to an example embodiment of thepresent disclosure;

FIG. 33 illustrates an enlarged view of the end effector of FIG. 32engaging a first negative heating terminal according to an exampleembodiment of the present disclosure;

FIG. 34 illustrates the track of the cartridge assembly subsystem ofFIG. 4 proximate the negative heating terminal coupling substationaccording to an example embodiment of the present disclosure;

FIG. 35 illustrates an inspection unit at the positive heating terminalassembly subsystem of the cartridge assembly substation of FIG. 4according to an example embodiment of the present disclosure;

FIG. 36 illustrates a perspective view of the control component couplingsubstation of the cartridge assembly substation of FIG. 4 according toan example embodiment of the present disclosure;

FIG. 37 illustrates a feeder unit of the control component couplingsubstation of FIG. 36 according to an example embodiment of the presentinvention;

FIG. 38 illustrates an enlarged view of a vibratory bowl of the supplyunit of FIG. 37 proximate an actuator according to an example embodimentof the present disclosure;

FIG. 39 illustrates an enlarged view of the vibratory bowl of FIG. 38proximate a gap defined in a pathway according to an example embodimentof the present disclosure;

FIG. 40 illustrates an enlarged view of a singulator of the supply unitof FIG. 37 and a feeder unit of the control component couplingsubstation of FIG. 36 in a first receiving position according to anexample embodiment of the present disclosure;

FIG. 41 illustrates an opposing enlarged view of the singulator and thefeeder unit of FIG. 40 wherein the feeder unit is in a second receivingposition according to an example embodiment of the present disclosure;

FIG. 42 illustrates a first assembly unit and a second assembly unit ofthe control component coupling substation of FIG. 36 according to anexample embodiment of the present disclosure;

FIG. 43 illustrates a first end effector of the first assembly unit ofFIG. 42 wherein a pivoting gripper is in a substantially horizontalconfiguration according to an example embodiment of the presentdisclosure;

FIG. 44 illustrates the first end effector of FIG. 43 wherein thepivoting gripper is in a substantially vertical configuration accordingto an example embodiment of the present disclosure;

FIG. 45 illustrates the track of the cartridge assembly subsystem ofFIG. 4 proximate the control component coupling substation of FIG. 36according to an example embodiment of the present disclosure;

FIG. 46 illustrates the track of FIG. 45 proximate a second processingportion according to an example embodiment of the present disclosure;

FIG. 47 illustrates a perspective view of the flow director couplingsubstation of the cartridge assembly substation of FIG. 4 according toan example embodiment of the present disclosure;

FIG. 48 illustrates an enlarged view of a supply unit of the flowdirector coupling substation of FIG. 47 according to an exampleembodiment of the present disclosure;

FIG. 49 illustrates a singulator of the supply unit of FIG. 48 accordingto an example embodiment of the present disclosure;

FIG. 50 illustrates a perspective view of a feeder unit of the flowdirector coupling substation of FIG. 47 according to an exampleembodiment of the present disclosure;

FIG. 51 illustrates a perspective view of a first assembly unit of theof the flow director coupling substation of FIG. 47 according to anexample embodiment of the present disclosure;

FIG. 52 illustrates a first end effector of the first assembly unit ofFIG. 51 according to an example embodiment of the present disclosure;

FIG. 53 illustrates a perspective view of the track of the cartridgeassembly subsystem of FIG. 4 proximate the flow director couplingsubstation of FIG. 47 according to an example embodiment of the presentdisclosure;

FIG. 54 illustrates a perspective view of the heating element couplingsubstation of the cartridge assembly substation of FIG. 4 according toan example embodiment of the present disclosure;

FIG. 55 illustrates a perspective view of a supply unit of the heatingelement coupling substation of FIG. 54 according to an exampleembodiment of the present disclosure;

FIG. 56 illustrates a side view of the supply unit of FIG. 55 accordingto an example embodiment of the present disclosure;

FIG. 57 illustrates a perspective view of a feeder unit, a firstassembly unit, and a second assembly unit of the heating elementcoupling substation of FIG. 54 according to an example embodiment of thepresent disclosure;

FIG. 58 illustrates an enlarged view of an end effector of the secondassembly unit of FIG. 57 according to an example embodiment of thepresent disclosure;

FIG. 59 illustrates an enlarged view of an engagement head and a gripperof the feeder unit of FIG. 57 according to an example embodiment of thepresent disclosure;

FIG. 60 illustrates a perspective view of the track of the cartridgeassembly subsystem of FIG. 4 proximate the heating element couplingsubstation of FIG. 55 according to an example embodiment of the presentdisclosure;

FIG. 61 illustrates a terminal fixation mechanism and a laser of a firstprocessing portion of the first assembly unit of FIG. 57 according to anexample embodiment of the present disclosure;

FIG. 62 illustrates an enlarged partial view of terminal effectors ofthe terminal fixation mechanism of FIG. 61 according to an exampleembodiment of the present disclosure;

FIG. 63 illustrates a perspective view of a reservoir and outer bodycoupling substation of the cartridge assembly substation of FIG. 4according to an example embodiment of the present disclosure;

FIG. 64 illustrates a perspective view of a reservoir supply unit of thereservoir and outer body coupling substation of FIG. 63 according to anexample embodiment of the present disclosure;

FIG. 65 illustrates a side view of a singulator of the reservoir supplyunit of FIG. 65 according to an example embodiment of the presentdisclosure;

FIG. 66 illustrates a perspective view of an outer body supply unit ofthe reservoir and outer body coupling substation of FIG. 63 according toan example embodiment of the present disclosure;

FIG. 67 illustrates a side view of a singulator of the outer body supplyunit of FIG. 66 according to an example embodiment of the presentdisclosure;

FIG. 68 illustrates an initial outer body feeder of a feeder unit of thereservoir and outer body coupling substation of FIG. 63 according to anexample embodiment of the present disclosure;

FIG. 69 illustrates a first outer body and reservoir substrate feederand first and second assembly units of the reservoir and outer bodycoupling substation of FIG. 63 according to an example embodiment of thepresent disclosure;

FIG. 70 illustrates a perspective view of a bending mechanism and anouter body gripper of the first assembly unit of FIG. 69 according to anexample embodiment of the present disclosure;

FIG. 71 illustrates a perspective view of a second outer body andreservoir substrate feeder of the reservoir and outer body couplingsubstation of FIG. 63 according to an example embodiment of the presentdisclosure;

FIG. 72 illustrates an enlarged view of the bending mechanism of FIG. 70according to an example embodiment of the present disclosure;

FIG. 73 illustrates a partial side view of the outer body crimping andinspection substation according to an example embodiment of the presentdisclosure;

FIG. 74 illustrates a perspective view of first and second crimper unitsof the outer body crimping and inspection substation according to anexample embodiment of the present disclosure;

FIG. 75 illustrates an enlarged perspective view of the processingportion included at each of the first and second crimper units of FIG.74 according to an example embodiment of the present disclosure;

FIG. 76 illustrates an enlarged view of a processing portion of a firsttransfer unit of the outer body crimping and inspection substation ofFIG. 73 according to an example embodiment of the present disclosure;

FIG. 77 illustrates a perspective view of an inspection and processingunit including an indexing table of the outer body crimping andinspection substation of FIG. 73 according to an example embodiment ofthe present disclosure;

FIG. 78 illustrates an enlarged view of a first angular stop of theindexing table of FIG. 77 according to an example embodiment of thepresent disclosure;

FIG. 79 illustrates an enlarged perspective view of a second angularstop of the indexing table of FIG. 77 according to an example embodimentof the present disclosure;

FIG. 80 illustrates a side view of a third angular stop of the indexingtable of FIG. 77 according to an example embodiment of the presentdisclosure;

FIG. 81 illustrates a side view a fourth angular stop of the indexingtable of FIG. 77 according to an example embodiment of the presentdisclosure;

FIG. 82 schematically illustrates a cartridge assembly method includingalternatingly feeding components from a first supply unit to first andsecond assembly units according to an example embodiment of the presentdisclosure;

FIG. 83 schematically illustrates a cartridge assembly method includingengaging an internal surface of a base of the cartridge with a carriageand transporting the cartridge on a track to a plurality of assemblysubstations via the carriage according to an example embodiment of thepresent disclosure;

FIG. 84 schematically illustrates a cartridge assembly method includingapplying a negative pressure to an outer body of the cartridge tofacilitation insertion of other components of the cartridge thereinaccording to an example embodiment of the present disclosure;

FIG. 85 schematically illustrates a controller according to an exampleembodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

The present disclosure provides descriptions of systems for assemblingaerosol delivery devices. The aerosol delivery devices may useelectrical energy to heat a material (preferably without combusting thematerial to any significant degree) to form an inhalable substance; sucharticles most preferably being sufficiently compact to be considered“hand-held” devices. An aerosol delivery device may provide some or allof the sensations (e.g., inhalation and exhalation rituals, types oftastes or flavors, organoleptic effects, physical feel, use rituals,visual cues such as those provided by visible aerosol, and the like) ofsmoking a cigarette, cigar, or pipe, without any substantial degree ofcombustion of any component of that article or device. The aerosoldelivery device may not produce smoke in the sense of the aerosolresulting from by-products of combustion or pyrolysis of tobacco, butrather, that the article or device most preferably yields vapors(including vapors within aerosols that can be considered to be visibleaerosols that might be considered to be described as smoke-like)resulting from volatilization or vaporization of certain components ofthe article or device, although in other embodiments the aerosol may notbe visible. In highly preferred embodiments, aerosol delivery devicesmay incorporate tobacco and/or components derived from tobacco. As such,the aerosol delivery device can be characterized as an electronicsmoking article such as an electronic cigarette or “e-cigarette.”

While the systems are generally described herein in terms of embodimentsassociated with aerosol delivery devices such as so-called“e-cigarettes,” it should be understood that the mechanisms, components,features, and methods may be embodied in many different forms andassociated with a variety of articles. For example, the descriptionprovided herein may be employed in conjunction with embodiments oftraditional smoking articles (e.g., cigarettes, cigars, pipes, etc.),heat-not-burn cigarettes, and related packaging for any of the productsdisclosed herein. Accordingly, it should be understood that thedescription of the mechanisms, components, features, and methodsdisclosed herein are discussed in terms of embodiments relating toaerosol delivery mechanisms by way of example only, and may be embodiedand used in various other products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Smoking articles of the present disclosure generally include a number ofcomponents provided within an outer shell or body. The overall design ofthe outer shell or body can vary, and the format or configuration of theouter body that can define the overall size and shape of the smokingarticle can vary. Typically, an elongated body resembling the shape of acigarette or cigar can be a formed from a single, unitary shell; or theelongated body can be formed of two or more separable pieces. Forexample, a smoking article can comprise an elongated shell or body thatcan be substantially tubular in shape and, as such, resemble the shapeof a conventional cigarette or cigar. In one embodiment, all of thecomponents of the smoking article are contained within one outer body orshell. Alternatively, a smoking article can comprise two or more shellsthat are joined and are separable. For example, a smoking article canpossess at one end a control body comprising a shell containing one ormore reusable components (e.g., a rechargeable battery and variouselectronics for controlling the operation of that article), and at theother end and removably attached thereto a shell containing a disposableportion (e.g., a disposable flavor-containing cartridge). More specificformats, configurations and arrangements of components within the singleshell type of unit or within a multi-piece separable shell type of unitwill be evident in light of the further disclosure provided herein.Additionally, various smoking article designs and component arrangementscan be appreciated upon consideration of the commercially availableelectronic smoking articles.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof, whereinsuch terms are also interchangeably used herein except where otherwisespecified.

As noted above, the aerosol delivery device may incorporate a battery orother electrical power source (e.g., a capacitor) to provide currentflow sufficient to provide various functionalities to the aerosoldelivery device, such as powering of a heater, powering of controlsystems, powering of indicators, and the like. The power source can takeon various embodiments. Preferably, the power source is able to deliversufficient power to rapidly heat the heating element to provide foraerosol formation and power the aerosol delivery device through use fora desired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices.

One example embodiment of an aerosol delivery device 100 is illustratedin FIG. 1. In particular, FIG. 1 illustrates a partially exploded viewof an aerosol delivery device 100 including a cartridge 200 and acontrol body 300. The cartridge 200 and the control body 300 can bepermanently or detachably aligned in a functioning relationship. Variousmechanisms may connect the cartridge 200 to the control body 300 toresult in a threaded engagement, a press-fit engagement, an interferencefit, a magnetic engagement, or the like. The aerosol delivery device 100may be substantially rod-like, substantially tubular shaped, orsubstantially cylindrically shaped in some embodiments when thecartridge 200 and the control body 300 are in an assembledconfiguration.

In specific embodiments, one or both of the cartridge 200 and thecontrol body 300 may be referred to as being disposable or as beingreusable. For example, the control body 300 may have a replaceablebattery or a rechargeable battery and thus may be combined with any typeof recharging technology, including connection to a typical alternatingcurrent electrical outlet, connection to a car charger (i.e., cigarettelighter receptacle), and connection to a computer, such as through auniversal serial bus (USB) cable. Further, in some embodiments thecartridge 200 may comprise a single-use cartridge, as disclosed in U.S.Pat. App. Pub. No. 2014/0060555 to Change et al., which is incorporatedherein by reference in its entirety.

FIG. 2 illustrates an exploded view of the control body 300 of theaerosol delivery device 100 according to an example embodiment of thepresent disclosure. As illustrated, the control body 300 may comprise acoupler 302, an outer body 304, a sealing member 306, an adhesive member308 (e.g., KAPTON® tape), a flow sensor 310 (e.g., a puff sensor orpressure switch), a control component 312, a spacer 314, an electricalpower source 316 (e.g., a battery, which may be rechargeable), a circuitboard with an indicator 318 (e.g., a light emitting diode (LED)), aconnector circuit 320, and an end cap 322. Examples of electrical powersources are described in U.S. Pat. App. Pub. No. 2010/0028766 byPeckerar et al., the disclosure of which is incorporated herein byreference in its entirety.

With respect to the flow sensor 310, representative current regulatingcomponents and other current controlling components including variousmicrocontrollers, sensors, and switches for aerosol delivery devices aredescribed in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. App. Pub. No. 2014/0270727 to Ampolini et al., whichis incorporated herein by reference in its entirety.

In one embodiment the indicator 318 may comprise one or more lightemitting diodes. The indicator 318 can be in communication with thecontrol component 312 through the connector circuit 320 and beilluminated, for example, during a user drawing on a cartridge coupledto the coupler 302, as detected by the flow sensor 310. The end cap 322may be adapted to make visible the illumination provided thereunder bythe indicator 318. Accordingly, the indicator 318 may be illuminatedduring use of the aerosol delivery device 100 to simulate the lit end ofa smoking article. However, in other embodiments the indicator 318 canbe provided in varying numbers and can take on different shapes and caneven be an opening in the outer body (such as for release of sound whensuch indicators are present).

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and WO 2010/003480 by Flick discloses a fluid flowsensing system indicative of a puff in an aerosol generating system; allof the foregoing disclosures being incorporated herein by reference intheir entireties. Further examples of components related to electronicaerosol delivery articles and disclosing materials or components thatmay be used in the present article include U.S. Pat. No. 4,735,217 toGerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan;U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231to Thorens et al.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat.Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Pat. App. Pub. Nos.2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 toWang; U.S. Pat. App. Pub. No. 2014/0261408 to DePiano et al.; WO2010/091593 to Hon; and WO 2013/089551 to Foo, each of which isincorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various embodiments, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

Returning to FIG. 1, the cartridge 200 is illustrated in an explodedconfiguration. As illustrated, the cartridge 200 may comprise a baseshipping plug 202, a base 204, a control component terminal 206, anelectronic control component 208, a flow director 210, an atomizer 212,a reservoir substrate 214, an outer body 216, a label 218, a mouthpiece220, and a mouthpiece shipping plug 222 according to an exampleembodiment of the present disclosure. The base 204 may be coupled to afirst end of the outer body 216 and the mouthpiece 220 may be coupled toan opposing second end of the outer body to substantially or fullyenclose the remaining components of the cartridge 200 therein. The base204 may be configured to engage the coupler 302 of the control body 300.In some embodiments the base 204 may comprise anti-rotation featuresthat substantially prevent relative rotation between the cartridge andthe control body as disclosed in U.S. Pat. App. Pub. No. 2014/0261495 toNovak et al., which is incorporated herein by reference in its entirety.

The base shipping plug 202 may be configured to engage and protect thebase 204 prior to use of the cartridge 200. Similarly, the mouthpieceshipping plug 222 may be configured to engage and protect the mouthpiece220 prior to use of the cartridge 200. The control component terminal206, the electronic control component 208, the flow director 210, theatomizer 212, and the reservoir substrate 214 may be substantiallyentirely retained within the outer body 216. The label 218 may at leastpartially surround the outer body 216 and include information such as aproduct identifier thereon.

The atomizer 212 may comprise a negative heating terminal 234 and apositive heating terminal 235, a liquid transport element 238 and aheating element 240. In this regard, the reservoir substrate 214 may beconfigured to hold an aerosol precursor composition. Representativetypes of aerosol precursor components and formulations are also setforth and characterized in U.S. Pat. No. 7,726,320 to Robinson et al.and U.S. Pat. Pub. Nos. 2013/0008457 to Zheng et al.; 2013/0213417 toChong et al. and 2014/0060554 to Collett et al., 2015/0020823 toLipowicz et al.; and 2015/0020830 to Koller, as well as WO 2014/182736to Bowen et al, the disclosures of which are incorporated herein byreference. Other aerosol precursors that may be employed include theaerosol precursors that have been incorporated in the VUSE® product byR. J. Reynolds Vapor Company, the BLU product by Lorillard Technologies,the MISTIC MENTHOL product by Mistic Ecigs, and the VYPE product by CNCreative Ltd. Also desirable are the so-called “smoke juices” forelectronic cigarettes that have been available from Johnson CreekEnterprises LLC. Embodiments of effervescent materials can be used withthe aerosol precursor, and are described, by way of example, in U.S.Pat. App. Pub. No. 2012/0055494 to Hunt et al., which is incorporatedherein by reference. Further, the use of effervescent materials isdescribed, for example, in U.S. Pat. No. 4,639,368 to Niazi et al.; U.S.Pat. No. 5,178,878 to Wehling et al.; U.S. Pat. No. 5,223,264 to Wehlinget al.; U.S. Pat. No. 6,974,590 to Pather et al.; and U.S. Pat. No.7,381,667 to Bergquist et al., as well as US Pat. Pub. Nos. 2006/0191548to Strickland et al.; 2009/0025741 to Crawford et al; 2010/0018539 toBrinkley et al.; and 2010/0170522 to Sun et al.; and PCT WO 97/06786 toJohnson et al., all of which are incorporated by reference herein.

The reservoir substrate 214 may comprise a plurality of layers ofnonwoven fibers formed into the shape of a tube encircling the interiorof the outer body 216 of the cartridge 200. Thus, liquid components, forexample, can be sorptively retained by the reservoir substrate 214. Thereservoir substrate 214 is in fluid connection with the liquid transportelement 238. Thus, the liquid transport element 238 may be configured totransport liquid from the reservoir substrate 214 to the heating element240 via capillary action or other liquid transport mechanisms.

As illustrated, the liquid transport element 238 may be in directcontact with the heating element 240. As further illustrated in FIG. 1,the heating element 240 may comprise a wire defining a plurality ofcoils wound about the liquid transport element 238. In some embodimentsthe heating element 240 may be formed by winding the wire about theliquid transport element 238 as described in U.S. Pat. App. Pub. No.2014/0157583 to Ward et al., which is incorporated herein by referencein its entirety. Further, in some embodiments the wire may define avariable coil spacing, as described in U.S. Pat. App. Pub. No.2014/0270730 to DePiano et al., which is incorporated herein byreference in its entirety. Various embodiments of materials configuredto produce heat when electrical current is applied therethrough may beemployed to form the heating element 240. Example materials from whichthe wire coil may be formed include Kanthal (FeCrAl), Nichrome,Molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi), Molybdenumdisilicide doped with Aluminum (Mo(Si,Al)₂), graphite and graphite-basedmaterials; and ceramic (e.g., a positive or negative temperaturecoefficient ceramic).

However, various other embodiments of methods may be employed to formthe heating element 240, and various other embodiments of heatingelements may be employed in the atomizer 212. For example, a stampedheating element may be employed in the atomizer, as described in U.S.Pat. App. Pub. No. 2014/0270729 to DePiano et al., which is incorporatedherein by reference in its entirety. Further to the above, additionalrepresentative heating elements and materials for use therein aredescribed in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. No. 8,881,737 toCollett et al., which is incorporated herein by reference, as notedabove.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Embodiments of microheaters thatmay be utilized are further described herein. Further microheaters andatomizers incorporating microheaters suitable for use in the presentlydisclosed devices are described in U.S. Pat. No. 8,881,737 to Collett etal., which is incorporated herein by reference in its entirety.

The negative heating terminal 234 and the positive heating terminal 235(e.g., positive and negative terminals) at the opposing ends of theheating element 240 are configured to form an electrical connection withthe control body 300 when the cartridge 200 is connected thereto.Further, when the control body 300 is coupled to the cartridge 200, theelectronic control component 208 may form an electrical connection withthe control body through the control component terminal 206. The controlbody 300 may thus employ the electronic control component 208 todetermine whether the cartridge 200 is genuine and/or perform otherfunctions. Further, various examples of electronic control componentsand functions performed thereby are described in U.S. Pat. App. Pub. No.2014/009678 to Sears et al., which is incorporated herein by referencein its entirety.

During use, a user may draw on the mouthpiece 220 of the cartridge 200of the aerosol delivery device 100. This may pull air through an openingin the control body 300 or in the cartridge. For example, in oneembodiment an opening may be defined between the coupler 302 and theouter body 304 of the control body 300, as described in U.S. Pat. App.Pub. No. 2014/0261408 to DePiano et al.; which is incorporated herein byreference in its entirety. However, the flow of air may be receivedthrough other parts of the aerosol delivery device 100 in otherembodiments. As noted above, in some embodiments the cartridge 200 mayinclude the flow director 210. The flow director 210 may be configuredto direct the flow of air received from the control body 300 to theheating element 240 of the atomizer 212.

A sensor in the aerosol delivery device 100 (e.g., a puff or flow sensorin the control body 300) may sense the puff. When the puff is sensed,the control body 300 may direct current to the heating element 240through a circuit including the negative heating terminal 234 and thepositive heating terminal 235. Accordingly, the heating element 240 mayvaporize the aerosol precursor composition directed to an aerosolizationzone from the reservoir substrate 214 by the liquid transport element238. Thus, the mouthpiece 220 may allow passage of air and entrainedvapor (i.e., the components of the aerosol precursor composition in aninhalable form) from the cartridge 200 to a consumer drawing thereon.

Various other details with respect to the components that may beincluded in the cartridge 200, are provided, for example, in U.S. Pat.App. Pub. No. 2014/0261495 to DePiano et al., which is incorporatedherein by reference in its entirety. In this regard, FIG. 7 thereofillustrates an enlarged exploded view of a base and a control componentterminal; FIG. 8 thereof illustrates an enlarged perspective view of thebase and the control component terminal in an assembled configuration;FIG. 9 thereof illustrates an enlarged perspective view of the base, thecontrol component terminal, an electronic control component, and heatingterminals of an atomizer in an assembled configuration; FIG. 10 thereofillustrates an enlarged perspective view of the base, the atomizer, andthe control component in an assembled configuration; FIG. 11 thereofillustrates an opposing perspective view of the assembly of FIG. 10thereof; FIG. 12 thereof illustrates an enlarged perspective view of thebase, the atomizer, the flow director, and the reservoir substrate in anassembled configuration; FIG. 13 thereof illustrates a perspective viewof the base and an outer body in an assembled configuration; FIG. 14thereof illustrates a perspective view of a cartridge in an assembledconfiguration; FIG. 15 thereof illustrates a first partial perspectiveview of the cartridge of FIG. 14 thereof and a coupler for a controlbody; FIG. 16 thereof illustrates an opposing second partial perspectiveview of the cartridge of FIG. 14 thereof and the coupler of FIG. 11thereof; FIG. 17 thereof illustrates a perspective view of a cartridgeincluding a base with an anti-rotation mechanism; FIG. 18 thereofillustrates a perspective view of a control body including a couplerwith an anti-rotation mechanism; FIG. 19 thereof illustrates alignmentof the cartridge of FIG. 17 with the control body of FIG. 18; FIG. 20thereof illustrates an aerosol delivery device comprising the cartridgeof FIG. 17 thereof and the control body of FIG. 18 thereof with amodified view through the aerosol delivery device illustrating theengagement of the anti-rotation mechanism of the cartridge with theanti-rotation mechanism of the connector body; FIG. 21 thereofillustrates a perspective view of a base with an anti-rotationmechanism; FIG. 22 thereof illustrates a perspective view of a couplerwith an anti-rotation mechanism; and FIG. 23 thereof illustrates asectional view through the base of FIG. 21 thereof and the coupler ofFIG. 22 thereof in an engaged configuration. Various other details withrespect to the components that may be included in the cartridge 200, areprovided, for example, in U.S. patent application Ser. No. 14/286,552 toBrinkley et al., filed May 23, 2014, which is incorporated herein byreference in its entirety.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

Note further that portions of the cartridge 200 illustrated in FIG. 1are optional. In this regard, by way of example, the cartridge 200 maynot include the flow director 210, the control component terminal 206,and/or the electronic control component 208 in some embodiments.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the battery and controller. An example embodiment of acarbon-based cartridge is provided in U.S. Pat. App. Pub. No.2013/0255702 to Griffith et al., which is incorporated herein byreference in its entirety.

As described above, cartridges of aerosol delivery devices may include anumber of components. Some of the components may be relatively smalland/or relatively delicate. Accordingly, precise manufacturingtechniques may be required to form the aerosol delivery devices. In thisregard, aerosol delivery devices have traditionally been formed viamanual assembly. However, use of manual labor to assemble aerosoldelivery devices suffers from certain detriments. In this regard, thequality of aerosol delivery devices produced via manual labor is only asgood as the workers performing the labor. Further, even skilled workersmay make errors from time-to-time. Additionally, manual labor may berelatively costly. Accordingly, as result of these issues and otherissues associated with the production of aerosol delivery devices viamanual labor, it may be desirable to produce aerosol delivery devices inan automated manner. Accordingly, automated production of cartridges foraerosol delivery devices is discussed hereinafter, which may provideenhanced repeatability, lower costs, and/or avoid other issues notedabove.

In this regard, FIG. 3 schematically illustrates an embodiment of asystem 400 for producing cartridges (e.g., the above-describedcartridges 200) for an aerosol delivery device (e.g., theabove-described aerosol delivery device 100). Note that the abovedescribed aerosol delivery device 100 is provided by way of example. Inthis regard, the methods, systems, and apparatuses described herein maybe employed to form various embodiments of cartridges that differ fromthe above described cartridges in one or more respects.

As illustrated, the system 400 may include various subsystems thatperform particular functions in the formation of the completedcartridges 200. Note that although the subsystems are illustrated asbeing separate from one another, the subsystems may overlap. Forexample, in some embodiments common equipment may perform two or morefunctions (e.g., assembly and filling or capping and labeling, etc.),rather than the particular functions being performed by separateequipment.

Further, the various subsystems and portions thereof may be separatelyusable. In this regard, although the subsystems and portions thereof aregenerally described herein as being usable together, this is by way ofexample. Accordingly, any of the subsystems or portions thereofdescribed herein may be usable by themselves or in any combination withsome or all of the other subsystems and portions thereof describedherein. Further, although particular embodiments of portions of thesubsystems are disclosed hereinafter, these embodiments are provided forexample purposes only. Accordingly, in some embodiments the subsystemsmay include fewer or additional portions. Thus, each portion of eachsubsystem, and each portion of the overall system is not required in allembodiments.

As illustrated, the subsystems may include a cartridge assemblysubsystem 402 configured to form unfilled cartridges 404 from components406 (e.g., the base 204, the heating terminals 234, 235, etc.). Acartridge filling subsystem 408 may fill the unfilled cartridges 404 toproduce filled cartridges 410. A cartridge capping subsystem 412 may capthe filled cartridges 410 to produce capped cartridges 414. A cartridgelabeling subsystem 416 may apply labels to the capped cartridges 414 tocomplete the completed cartridges 200.

The system 400 may additionally include an inspection subsystem 418. Theinspection subsystem 418 may inspect the components 406, the unfilledcartridges 404, the filled cartridges 410, the capped cartridges 414,and/or the completed cartridges 200. Further, in some embodiments thecartridges may be inspected at intermediate states of completion at oneor more of the cartridge assembly subsystem 402, the cartridge fillingsubsystem 408, the cartridge capping subsystem 412, and the cartridgelabeling subsystem 416. Accordingly, the cartridges 200 and componentsthereof may be inspected before, during, and after completion thereof.

The system may further at least one controller 417. The controller 417may be configured to control the cartridge assembly subsystem 402, thecartridge filling subsystem 408, the cartridge capping subsystem 412,and/or the cartridge labeling subsystem 416. In this regard, thecontroller may be configured to receive data from one or more of thesensors described herein and output instructions based thereon, inaddition to otherwise directing the operations described herein.

Note that some or all of the system 400 may be automated. In thisregard, as described hereinafter, robotic apparatuses may be employed insome embodiments of the system 400. The robotic apparatuses may beprovided from various robotic manufacturers including, by way ofexample, DENSO Robotics of Long Beach, Calif., FANUC of Rochester Hills,Mich., Mitsubishi Electric Automation of Vernon Hills, Ill., EPSONRobots of Carson, Calif., and Siemens Automation Technology of Munich,Germany.

An example embodiment of the cartridge assembly subsystem 402 isschematically illustrated in FIG. 4. Note that the particularembodiments of substations and positions thereof may vary from thosedescribed below and illustrated in FIG. 4. Further, the particularoperations employed as well as the order thereof may also vary. Theequipment employed to assemble a cartridge may depend on the particularconfiguration of the end-product cartridge. In this regard, thecartridge 200 described above and referenced hereinafter is discussedfor example purposes only. Additionally, although the descriptiongenerally refers to the portions of the cartridge assembly subsystem 402as substations, it should be understood that the various assemblyoperations discussed herein may be performed by a single device,apparatus, or substation, or distributed across multiple devices,apparatuses, and substations. Accordingly, the description providedbelow is for example purposes only, and the equipment and operations andorder thereof employed may vary without departing from the scope of thedisclosure. Further, it should be understood that various substationsand operations performed at each of the substations should be viewed asindividual inventive aspects. In this regard, although the individualsubstations and operations are generally described herein as being partof a system, each of the substations may operate independently of theother substations discussed herein and/or be combined with othersubstations.

As illustrated in FIG. 4, the cartridge assembly subsystem 402 mayinclude a base load substation 502, a control component terminalcoupling substation 504, a negative heating terminal coupling substation506, a positive heating terminal coupling substation 508, a controlcomponent coupling substation 510, a flow director coupling substation512, a heating element coupling substation 514, a reservoir and an outerbody coupling substation 516, and an outer body crimping and inspectionsubstation 518. As illustrated further illustrated in FIG. 4, thecontroller 417 may be configured to control one or more of thesubstations 502-518 of the cartridge assembly subsystem 402.

Briefly, the base load substation 502 may be configured to receive abase (e.g., the base 204) and orient the base for assembly with thevarious other components of the cartridge. The control componentterminal coupling substation 504, the negative heating terminal couplingsubstation 506, and the positive heating terminal coupling substation508 may be respectively configured to couple a control componentterminal (e.g., the control component terminal 206) a negative heatingterminal (e.g., the negative heating terminal 234) and a positiveheating terminal (e.g., the positive heating terminal 235) to the base204. The control component coupling substation 510 may be configured tocouple a control component (e.g., the electronic control component 208)to the control component terminal 206. The flow director couplingsubstation 512 may be configured to couple a flow director (e.g., theflow director 210) to the control component 208, the negative andpositive heating terminals 234, 235, and/or other components. Theheating element coupling substation 514 may be configured to couple aheating element (e.g., the heating element 240) to the negative andpositive heating terminals 234, 235. The reservoir and outer bodycoupling substation 516 may be configured to bend the liquid transportelement (e.g., the liquid transport element 238), to wrap a reservoir(e.g., the reservoir 214) around the atomizer (e.g., the atomizer 212)and to engage an outer body (e.g., the outer body 216) to the base 204.The outer body crimping and inspection substation 518 may be configuredto crimp the outer body 216 to the base 204 and inspect the cartridges200.

The cartridge assembly subsystem 402 may assemble the cartridge (e.g.,the cartridge 200) in a variety of manners. For example, in oneembodiment the cartridge 200 may be assembled generally upwardly fromthe base 204. In other words, components may be inserted into orotherwise coupled to the base 204, or coupled to components previouslycoupled to the base, to build up the cartridge 200 therefrom.

In this regard, as further illustrated in FIG. 4, in one embodiment thecartridge assembly subsystem 402 may include a transport systemcomprising a track 602 and at least one carriage 604 configured toengage the track (e.g., by riding on the track) and to cooperatetherewith to move between the assembly substations 502. Preferably,multiple carriages 604 may be employed such that each of the substations502-518 of the cartridge assembly subsystem 402 may simultaneouslyoperate to simultaneously assemble a plurality of cartridges 200.Further, the carriages 604 may return to an initial starting pointupstream of the base load substation following completion of a cartridge200, such that the carriages may be repeatedly employed to assemblemultiple cartridges.

The carriages 604 may be configured to engage the base 204 such that aremainder of the components of the cartridge 200 may be coupled thereto.In this regard, as discussed below, the base 204 may be engaged with thecarriage 604 at the base load substation 502. Thereafter additionalcomponents may be generally directed downwardly into contact with thebase 204, or components previously coupled to the base, such that thecartridge 200 is built generally upwardly from the base as variouscomponents are coupled thereto at the remaining substations 504-518.

Accordingly, the carriages 604 may be configured to grasp the base 204.In this regard, each carriage 604 may include at least one engagementhead configured to engage the base 204. In some embodiments eachcarriage 604 may include a plurality of engagement heads, such thatmultiple cartridges may be assembled thereon in order to improveassembly speed and efficiency. For example, as illustrated in FIG. 5, insome embodiments the carriages 604 may each include a body portion 606and two engagement heads 608 a, 608 b extending therefrom. Thereby, eachcarriage 604 may be configured for assembly of two cartridges thereon.

The engagement heads 608 a, 608 b may be configured to engage arespective base 204 in a firm manner that does not interfere withattachment of the other components to the base. In this regard, in someembodiments the engagement heads 608 a, 608 b may be configured toengage an internal surface 242 of an attachment end 244 of each base 204(see, FIG. 1). Thereby, an external periphery of each base 204 may beexposed to facilitate attachment of components thereto. In this regard,the components may couple to an inner end 246 (see, FIG. 1) of the base204 during assembly of the cartridges, and hence engagement of theinternal surface 242 of each base 204 with the carriage 604 mayfacilitate attachment of components thereto, by providing forsubstantially unimpeded access to the inner end.

In particular, as illustrated in FIG. 5, each engagement head 608 a, 608b may comprise a collet 610 a, 610 b, with each collet comprising aplurality of sections 612 separated by slots at a top portion thereof. Acollar 614 a, 614 b may extend around the sections 612 to prevent thecollets 610 a, 610 b from falling downwardly through the body portion606. The sections 612 of each collet 610 a, 610 b may be configured toengage the internal surface 242 of the attachment end 244 of the base204 (see, e.g., FIG. 1), for example, via an interference fit. In theillustrated embodiment, each collet 610 a, 610 b includes four sections612. However, as may be understood, the collets 610 a, 610 b may includevarious other numbers of sections 612 in other embodiments. The sections612 of each collet 610 a, 610 b may be configured to flex inwardlyduring engagement with the base 204 and then apply outward pressureagainst the internal surface 242 of the base such that the base isretained in engagement therewith. For example, the internal surface 242of each base 204 may define one or more ribs which the sections 612 ofthe collets 610 a, 610 b may engage such that the cooperationtherebetween securely holds the base to the respective collet. Acartridge including a base with such ribs is disclosed in U.S. Pat. App.Pub. No. 2014/0261495 to Novak et al., which is incorporated herein byreference in its entirety.

FIG. 6 illustrates a bottom view of the carriage 604. As illustrated,the collets 610 a, 610 b may extend to a bottom portion of the carriage604. A clip 616 a, 616 b may secure each collet 610 a, 610 b at anopposing end. Thereby, the collar 614 a, 614 b and the clip 616 a, 616 bcooperatively retain each collet 610 a, 610 b at a fixed position withrespect to the body portion 606. As further illustrated in FIG. 6, thecarriage 604 may define one or more alignment apertures 618 a, 618 b. Asdiscussed below, locking pins may be configured to engage the alignmentapertures 618 a, 618 b to releasably lock the carriage 604 at each ofthe assembly substations 502-518. As illustrated, in one embodiment thealignment apertures 618 a, 618 b may be defined by the collets 610 a,610 b. In this regard, when the alignment apertures 618 a, 618 b engagelocking pins, the collets 610 a, 610 b may be directly aligned with thelocking pins such that the partially-assembled cartridges are preciselypositioned and thereby the cartridges may be precisely assembled. Insome embodiments the collets 610 a, 610 b may be formed fromlife-science grade polyether ether ketone (PEEK), which provides thesections 612 thereof with resiliency that enables coupling with bases asdescribed above and which may be substantially hard so as to avoid wearfrom repeated coupling and decoupling with the bases 204, which may alsocomprise a plastic or other polymeric material. However, the alignmentapertures 618 a, 618 b may receive locking pins comprising metal orother relatively harder substances. Thus, in order to prevent wear tothe collets 610 a, 610 b at the alignment apertures 618 a, 618 b, insome embodiments a hardened ring 620 a, 620 b may be received withineach collet at the alignment aperture 618 a, 618 b so as to avoid wearthereto.

As illustrated in FIG. 5, each carriage 604 may further comprise one ormore bumpers 622. In this regard, in some embodiments the carriages 604may be positioned adjacent to or in contact with one another at one ormore locations along the track 602 such that the carriages are ready forusage in the next substation. For example, as illustrated in FIG. 4, insome embodiments the track 602 may include a staging area 602 a at whichthe carriages 604 are temporarily collected. In some embodiments thestaging area 602 a may be positioned upstream of the base loadsubstation 502, such that one or more of the carriages 604 may betemporarily collected prior to moving through the substations 502-518.Thereby, the bumpers 622 may protect the body portions 606 of thecarriages 604 and/or the cartridge assemblies/subassemblies carriedthereby, from damage due to contact between the carriages.

As further illustrated in FIG. 5, the carriage 604 may additionallyinclude a storage module 624. The storage module 624 may be configuredto store cartridge identification and status information for each of thecartridges 200 (or partially-assembled cartridges) coupled to thecarriage 604. In some embodiments the storage module 624 may comprise aradio-frequency identification (RFID) chip or other wirelesstransponder. In this regard, the storage module 624 may be utilized totrack information for each of the partially-assembled cartridges on thatcarriage 604 during their assembly. The storage module 624 may include aunique identifier for the carriage 604 and/or each of the cartridges 200undergoing assembly, and various other information may be stored andassociated therewith. Thereby, the storage module 624 may storeinformation with respect to each cartridge 200 during assembly thereof.Thus, as each substation 502-518 completes operations on thepartially-assembled cartridges, data may be updated and written to thestorage module 624. If an assembly step or a post-assembly stepinspection indicates that an assembly operation was not properlyperformed on one of the partially-assembled cartridges or thepartially-assembled cartridge is determined to differ from the desiredspecifications, the operations or tasks at all substations downstreamfrom that substation may not be performed on that partially-assembledcartridge in order to avoid potentially damaging the downstreamsubstations and to avoid wasting usage of additional components on thedefective partially-assembled cartridge. The information stored in thestorage module 624 may also be employed to determine where to place thecompleted cartridges 200 following removal from the carriages 604 (e.g.,for filling and/or labeling purposes). The storage module 624 may havedata stored therein cleared following removal of the completedcartridges 200 such that the cycle may be repeated during the assemblyof new cartridges on each carriage 604.

FIG. 7 illustrates an opposing perspective view of the carriage 604after engagement of a first base 204 a with the first engagement head608 a and after engagement of a second base 204 b with the secondengagement head 608 b at the base load substation 502, as discussedbelow. As illustrated, the carriage 604 may further comprise a locatormodule 626. The locator module 626 may be employed to detect a presenceof the carriage 604 along the track 602 at each of the substations502-518 as the carriage moves therealong such that the substations knowwhen the carriage is available and positioned to perform cartridgeassembly operations. In some embodiments the locator module 626 maycomprise a ferromagnetic material such as steel. Further, to avoidinterference with detection of the locator module 626, the body portion606 of the carriage 604 may comprise a non-ferromagnetic material. Insome embodiments the body portion 606 of the carriage 604 may comprisean electrostatic dissipative material such as polyoxymethylene soldunder the name DELRIN by E.I. du Pont de Nemours of Wilmington, Del. Inthis regard, usage of an electrostatic dissipative material may avoidbuildup of a static charge on the carriage 604 as a result of movementalong the track 602. Such an electrostatic charge could potentiallydischarge and damage one of the substations 502-518.

As further illustrated in FIG. 7, in some embodiments the carriage 604may include a stop bar 628. The stop bar 628 may be configured to engagea stop pin at one or more locations along the track 602 so as totemporarily hold the carriage 604 at a desired position. For example,the stop pin may engage the stop bar 628 to temporarily stop movement ofthe carriage 604 and allow for lifting of the carriage.

Accordingly, the track 602 may be configured to transport the carriages604 therealong to the various assembly substations 502-518. In thisregard, the empty cartridges 604 may first be directed to the base loadsubstation 502. The base load substation 502 may be configured torotationally align a base 204 with each engagement head 608 a, 608 b ofthe carriage 604 and engage the bases with the engagement heads.

In this regard, FIG. 8 illustrates a perspective view of the base loadsubstation 502. As illustrated, the base load substation 502 may includea supply unit 702, a feeder unit 704, a first assembly unit 706 a, and asecond assembly unit 706 b. Briefly, the supply unit 702 may beconfigured to provide a plurality of components (e.g., the bases 204).The feeder unit 704 may be configured to receive the bases 204 from thesupply unit 702 and alternatingly feed the bases 204 to the firstassembly unit 706 a and the second assembly unit 706 b. The firstassembly unit 706 a and the second assembly unit 706 b may each beconfigured to assemble the components (e.g., the bases 204) intocartridges 200 for an aerosol delivery device 100, for example, bycoupling the bases 204 to the carriage 604 to allow for coupling ofother components thereto thereafter.

In this regard, FIG. 9 illustrates an enlarged view of the supply unit702. As illustrated, the supply unit 702 may be configured to supply aplurality of the bases 204. In some embodiments the supply unit 702 mayinclude a vibratory arrangement. For example, the vibratory arrangementmay include a vibratory hopper 708, a vibratory bowl 710, and a supplytrack 712. In some embodiments the vibratory hopper 708, the vibratorybowl 710, and/or the supply track 712 may be manufactured by PerformanceFeeders, Inc. of Oldsmar, Fla.

The bases 204 may be loaded into the vibratory hopper 708. As thevibratory hopper 708 vibrates, the bases 204 gradually travel under agate 714 and fall into the vibratory bowl 710 so as to provide thevibratory bowl with a substantially constant supply of the bases. Inthis regard, a component level sensor 716 may detect a level of thebases 204 within the vibratory bowl 710. Thereby, the vibratory hopper708 may start and stop based on the level of the bases 204 within thevibratory bowl 710 as detected by the component level sensor 716. Thevibratory hopper 708 may thus maintain a substantially constant level ofthe bases 204 within the vibratory bowl 710 as the bases are transportedtherefrom.

The vibratory bowl 710 may define a pathway 718 configured to arrangethe bases 204 in a serially-aligned stream 720. In this regard, thevibratory motion of the vibratory bowl 710 may direct the bases 204upwardly along the pathway 718, which may narrow such that some basesfall therefrom and the bases that remain on the pathway becomeserially-aligned. The vibratory bowl 710 may be configured to arrangethe bases 204 such that the attachment end 244 is oriented downwardlyand the inner end 246 is oriented upwardly (see, FIG. 1).

However, some bases 204 in the serially-aligned stream 720 may beoriented upside down or otherwise oriented in a manner that differs fromthe desired orientation. In this regard, the supply unit 702 may furthercomprise an actuator 724 configured to individually remove or realignthe bases 204 in the serially-aligned stream 720 when the bases aremisaligned in a direction. In one embodiment the actuator 724 maycomprise a nozzle 726 configured to direct a flow of air at each base204 that is misaligned to remove the base from the pathway 718 or pushthe base into proper alignment. In some embodiments the nozzle 726 maybe oriented so as to only impact those bases 204 that are misalignedwith the flow of air (i.e., if a base is misaligned, it will be impactedby the flow of air from the nozzle and removed or re-aligned). Inanother embodiment the supply unit 702 may further comprise anorientation sensor 722 (e.g., a camera) configured to determine analignment of the bases 204 on the pathway 718, and the actuator 724 maybe actuated in response thereto when a misaligned base is detected.

Accordingly, each of the bases 204 in the serially-aligned stream 720may be properly oriented downstream of the actuator 724. The bases 204removed by the actuator 724 may be directed back into the vibratory bowl710 such that the bases 204 may be returned to the pathway 718. In someembodiments the pathway may define a gap or other feature configured toremove the components from the serially-aligned stream when thecomponents are misaligned in a second direction. For example, such a gapor other feature may be configured to allow the bases resting on theirouter circumference to roll off of the pathway.

Accordingly, the serially-aligned stream 720 of the bases 204 may bedirected to the supply track 712, which may maintain the bases in theupwardly-extending orientation and in the single-file arrangement. Insome embodiments the supply track 712 may comprise a vibratory supplytrack to facilitate movement of the bases 204 therealong. Asillustrated, the supply track 712 may include a full sensor 726configured to detect whether the supply track is full of the bases 204.In this regard, when the full sensor 726 senses that the supply track712 is full, the vibratory bowl 710 may be shut off. Further, the supplytrack 712 may include a low level sensor 728 configured to detect whenthe supply track is running low on the bases 204. In this regard, whenthe low level sensor 728 detects a low level of the bases 204 in thesupply track 712, an indicator 730 (see, FIG. 8) may be illuminated toinform an operator that the base load substation 502 is running low onthe bases 204, such that the operator may be informed that it is time torefill the vibratory hopper 708. In some embodiments the full sensor 726and the low level sensor 728 may comprise optical sensors that includean emitter and a receiver configured to detect a presence or absence ofa base 204 therebetween.

Further, as illustrated in FIG. 10, the supply unit 702 may include asingulator 732 configured to singulate the bases 204 from theserially-aligned stream 720. In this regard, the singulator 732 includesa stop 734 (e.g., comprising first and second pins in the illustratedembodiment) and a vertical actuator 736. The vertical actuator 736 maybe configured to raise stop 734 to an upper position and lower the stopto a lower position. The vertical actuator 736 may default to the lowerposition such that the stop 734 blocks the base 204 at the end of theserially-aligned stream 720 from moving. However, the vertical actuator736 may momentarily raise the stop 734 to the upper position to allowthe base 204 at the end of the serially-aligned stream to passthereunder. Thereby, the base 204 passing under the stop 734 may bedelivered to the feeder unit 704. The vertical actuator 736 may returnthe stop 734 to the lower position after the base 204 passes thereunder,such that a remainder of the serially-aligned stream 720 is blocked.This cycle may be repeated to singulate each of the bases 204 from theserially-aligned stream 720 and deliver individual bases to the feederunit 704.

FIGS. 11 and 12 illustrate the feeder unit 704. In some embodiments thefeeder unit 704 may comprise a rotary member 738, such as a rotarytable. A first engagement head 740 a and a second engagement head 740 bmay be coupled to the rotary member 738 and each configured toalternatingly receive one of the bases 204 from the supply unit 702. Inthis regard, the first engagement head 740 a may define a first pocket742 a (see, FIG. 11) and the second engagement head 740 b may define asecond pocket 742 b (see, FIG. 11). As illustrated, in some embodimentsthe rotary member 738 may comprise a first arm 744 a and a second arm744 b. The first engagement head 740 a may be coupled to the first arm744 a and the second engagement head 740 b may be coupled to the secondarm 742 b.

FIG. 12 illustrates the rotary member 738 in a first receiving positionand FIG. 11 illustrates the rotary member in a second receivingposition, between which the rotary member may be configured to swivel orrotate about a particular point. In the first receiving position, thefirst engagement head 740 a is positioned proximate the singulator 732.Thereby, a first base 204 a may be singulated from the serially-alignedstream 720 and delivered into the first pocket 742 a in the firstengagement head 740 a. A base load sensor 745 (e.g., an optical sensor)may detect that the first base 204 a has been delivered to the firstengagement head 740 a.

After the first base 204 a is received in the first engagement head 740a, the rotary member 738 may swivel (e.g., by rotating counterclockwisewhen viewed from above) to a first delivery position, which correspondsto the second receiving position, and which is illustrated in FIG. 11.As the rotary member 738 swivels, negative pressure may be applied tothe first pocket 742 a. Thereby, the negative pressure may assist inretaining the first base 204 a on the rotary member 738 during swivelingmovement thereof. Accordingly, the first base 204 a may be moved to thefirst delivery position.

FIG. 13 illustrates the first assembly unit 706 a and the secondassembly unit 706 b. As illustrated, the first assembly unit 706 a mayinclude a first robotic arm 746 a and a first end effector 748 a coupledthereto. Similarly, the second assembly unit 706 b may include a secondrobotic arm 746 b and a second end effector 748 b coupled thereto.

The first end effector 748 a may be configured to engage the first base204 a and deliver the first base to a carriage 604 engaged with thetrack 602 via movement of the first robotic arm 748 a. Thus, the firstassembly unit 706 a may be positioned such that the first robotic arm746 a is configured to move the first end effector 748 a between thefeeder unit 704 and the track 602. In this regard, when the rotarymember 738 is in the first delivery position (see, FIG. 11), the firstrobotic arm 746 a may direct the first end effector 748 a intoengagement with the first base 204 a in the first engagement head 740 a.In this regard, in some embodiments the first end effector 748 a may beconfigured to apply a negative pressure to the inner end 246 (see,FIG. 1) of the first base 204 a such that the first base becomes engagedtherewith. Further, the first engagement head 740 a may stop applyingnegative pressure to the first pocket 742 a when the rotary member 738is in the first delivery position to facilitate transfer of the firstbase 204 a to the first end effector 748 a. Thereby, the first roboticarm 746 a may lift the first base 204 a via the first end effector 748a.

As illustrated in FIG. 12, the first assembly unit 706 a may include afirst rotational alignment imaging device 750 a and the second assemblyunit 706 b may include a second rotational alignment imaging device 750b. In this regard, after the first robotic arm 746 a and the first endeffector 748 a lift the first base 204 a, the first robotic arm may movethe first end effector such that the first base is positioned above thefirst rotational alignment imaging device 750 a. Thereby, the firstrotational alignment imaging device 750 a may detect a rotationalorientation of the first base 204 a based on image of the attachment end244 of the base. Thereby, the first robotic arm 746 a may rotate the endeffector 748 a such that the first base 204 a defines a desiredrotational orientation.

For example, FIG. 14 illustrates an enlarged view of a base 204 in aproper orientation relative to a machine direction 752, whichcorresponds to a direction of movement of the carriage 604 and the basealong the track 602 at any given point thereon. As illustrated, the base204 may define a negative heating terminal aperture 248 a configured toreceive the negative heating terminal 234, a positive heating terminalaperture 248 b configured to receive the positive heating terminal 235,and a control component terminal aperture 250 configured to receive thecontrol component terminal 206. The negative heating terminal aperture248 a may be positioned downstream of the positive heating terminalaperture 248 b, with the control component terminal aperture 250positioned therebetween when the base 204 is properly oriented withrespect to the carriage 604.

Accordingly, the carriage 604 may be positioned for receipt of the firstbase 204 a following rotational alignment thereof. In this regard, FIG.15 illustrates an enlarged view of the track 602 proximate the base loadsubstation 502. As illustrated, the first assembly unit 706 a mayinclude a first processing portion 754 a and the second assembly unit706 b may include a second processing portion 754 b positioned proximatethe track 602. In particular, each carriage 604 may first be directedthrough the first processing portion 754 a followed by the secondprocessing portion 754 b. Operations relating to the first base 204 aand the first engagement head 608 a (see, FIG. 7) are conducted at thefirst processing portion 754 a, whereas operations relating to thesecond base 204 b and the second engagement head 608 b (see, FIG. 7) areconducted at the second processing portion 754 b.

Accordingly, the carriage 604 may be directed into the base loadsubstation 502 along the track 602. The carriage 604 may thereby enterthe first processing portion 754 a. As illustrated in FIG. 16, thecarriage 604 may be directed past a carriage sensor 756 a, which maycomprise a light emitter and detector, and which detects presence of thecarriage 604. Thereby, for example, an additional carriage may bereleased from the staging area 602 a (see, FIG. 4) following detectionof the carriage 604, such that a continuing flow of the carriages may bedirected along the track 602.

As illustrated in FIG. 15, after passing the carriage sensor 756 a, thecarriage 604 may be directed past an initial locator sensor 758 aconfigured to detect the locator module 626 and verify the presence andlocation of the carriage. An initial stop 760 a may then stop thecarriage 604 by engaging an initial stop pin 762 a with the stop bar 628on the carriage 604 (see, FIG. 7). Thereby, when a downstream carriageis clear, the carriage 604 may be released from the initial stop 760 aby retracting the initial stop pin 762 a.

Accordingly, the track 602 may move the carriage 604 until the carriageengages a lift stop 764 a. In particular the stop bar 628 on thecarriage (see, FIG. 7) may engage a lift stop pin 766 a. While thecarriage 604 is stopped, a stop locator sensor 768 a may detect thelocator module 626 and verify the presence and location of the carriage.The track 602 may include a lifter mechanism 770 a configured to liftthe carriage 604 after the presence and location thereof is verified bythe stop locator sensor 768 a. In this regard, the track 602 maycomprise a conveyor including two parallel conveyor belts 628 which mayextend on opposing sides of the lifter mechanism 770 a and which movethe carriages 604 along the track. Accordingly, the lifter mechanism 770a may lift the carriage 604 from the conveyor belts 628. Exampleembodiments of conveyors and conveyor belts are available from MONTECHof Derendingen, Switzerland.

The lifter mechanism 770 a may comprise a first locking pin 772 a and asecond locking pin 774 a configured to engage the carriage 604. Inparticular, the first locking pin 772 a may be configured to engage thefirst alignment aperture 618 a defined by the first collet 610 a (see,FIG. 6), and the second locking pin 774 a may be configured to engagethe second alignment aperture 618 b defined by the second collet 610 b(see, FIG. 6) to releasably lock the carriage 604 at the base loadsubstation 502. Accordingly, the first engagement head 608 a may bealigned with the first locking pin 772 a and the second engagement head608 b may be aligned with the second locking pin 774 a. Thereby, theposition of the engagement heads 608 a, 608 b is precisely controlled,without regard to the overall tolerance of the carriage 604, due to thecollets 610 a, 610 b being configured to engage both the locking pins772 a, 774 a and the bases 204 a, 204 b. In this regard, while thecarriage 604 is lifted and engaged by the lifter mechanism 770 a, thefirst robotic arm 746 a may direct the first base 204 a into engagementwith the first engagement head 608 a with the first base properlyrotationally oriented as described above. At such time, the first endeffector 748 a may stop applying negative pressure, such that the firstbase 204 a may release therefrom and remain in engagement with the firstengagement head 608 a. The robotic arm 748 a may then return to aninitial position proximate the rotary member 738.

After the robotic arm 748 a completes the base engagement operation, astorage transceiver 776 a may write code to the storage module 624indicating whether or not the first base 204 a was properly coupled tothe first engagement head 608 a. In this regard, a component presencesensor 778 a (e.g., comprising a light emitter and receiver; see FIG.15) may detect whether the first base 204 a is engaged with the firstengagement head 608 a following movement of the first robotic arm 746 aas described above. For example, the component presence sensor 778 a maydetect whether or not the base 204 a is present while the carriage 604is lifted by the lifter mechanism 770 a. In instances in which the firstbase 204 a is not properly engaged with the engagement head 608 a, thesubstations downstream of the base load substation 502 may not performadditional operations that would be otherwise conducted on the firstbase 204 a. In other words, in light of the first base 204 a beingimproperly attached or missing, the substations downstream of the baseload substation 502 may not attempt to couple additional components tothe base that should be on the carriage, so as to avoid damage to theremaining substations and waste of components.

Thereafter, the lifter mechanism 770 a may release the carriage 604 bylowering the carriage back onto the conveyor belts 628. At such time thecarriage 604 may be directed to the second processing portion 754 b. Thesecond processing portion 754 b may comprise the same componentsincluded in the first processing portion 754 a. For example, asillustrated in FIG. 16, the second processing portion 754 b may includea carriage sensor 756 b, an initial locator sensor 758 b, an initialstop 760 b including an initial stop pin 762 b, a lift stop 764 bincluding a lift stop pin 766 b, a stop locator sensor 768 b, a liftermechanism 770 b including a first locking pin 772 b and a second lockingpin 774 b. Accordingly, the second processing portion 754 b may operatein substantially the same manner as the first processing portion 754 a,and hence the description thereof will not be repeated. However, as maybe understood, the carriage 604 may be lifted by the lifter mechanism770 b such that the second base 204 b may be engaged with the secondengagement head 608 b.

In this regard, as illustrated in FIG. 11, while the first engagementhead 740 a is in the first delivery position, the second engagement head740 b is in the second receiving position at which the second engagementhead is positioned proximate the singulator 732. Thereby, one of thebases 204 may be singulated from the serially-aligned stream 720 anddelivered into the second pocket 742 b in the second engagement head 740b. The base load sensor 745 may detect that a base 204 (e.g., the secondbase 204 b) has been delivered to the second engagement head 740 b.While the second engagement head 740 b receives the second base 204 b,the first engagement head 740 a may feed the first base 204 a receivedtherein to the first assembly unit 706 a in the manner described above.The rotary member 738 may then swivel (e.g., by rotatingcounterclockwise when viewed from above) back to the first receivingposition such that the first engagement head 740 a may receive anotherbase 204.

While the first engagement head 740 a receives one of the bases 204, thesecond engagement head 740 b may feed the second base 204 b receivedtherein to the second assembly unit 706 b. Accordingly, the rotarymember 738 may swivel back and forth such that the bases areindividually delivered by the feeder unit 704 to the first assembly unit706 a and the second assembly unit 706 b. Thus, the first receivingposition may correspond to the second delivery position and the secondreceiving position may correspond to the first delivery position.

Thereby, the second assembly unit 706 b may engage the second base 204 bwith the second engagement head 608 b in the manner described above withrespect to the first assembly unit 706 a. In this regard, briefly, thesecond robotic arm 746 b may engage the second base 204 b via the secondend effector 748 b, lift and rotate the second base to the properorientation based on an image provided by the second rotationalalignment imaging device 750 b, and engage the second base with thesecond engagement head 608 b in the proper orientation while the liftermechanism 770 b engages the carriage 604. At such time, the second endeffector 746 b may stop applying negative pressure, such that the secondbase 204 b may release therefrom and remain in engagement with thesecond engagement head 608 b. The second robotic arm 746 b may return toan initial position proximate the rotary member 738.

After the second robotic arm 746 b completes the base engagementoperation, a second storage transceiver 776 b may write code to thestorage module 624 indicating whether or not the second base 204 b wasproperly coupled to the second engagement head 608 b. In this regard, acomponent presence sensor 778 b (e.g., comprising a light emitter andreceiver; see FIG. 15) may detect whether the second base 204 b isengaged with the second engagement head 608 b following movement of thesecond robotic arm 746 b as described above. For example, the componentpresence sensor 778 b may detect whether or not the base 204 b ispresent while the carriage 604 is lifted by the lifter mechanism 770 b.In instances in which the second base 204 b is not properly engaged withthe engagement head 608 b, the substations downstream of the base loadsubstation 502 may not perform additional operations that would beotherwise conducted on the second base so as to avoid damage to theremaining substations and waste of components.

The lifter mechanism 770 b may lower such that the track 602 transportsthe carriage 604 including the first and second bases 204 a, 204 bcoupled thereto downstream. The carriage 604 may be directed out of thebase load substation 502 by the track 602. As illustrated in FIG. 4, insome embodiments the carriage 604 may be directed to the controlcomponent terminal coupling substation 504 after the base loadsubstation 502. Note that some of the above-described operations may beconducted simultaneously. In this regard, the bases may be singulated,etc. while the carriages are directed along the track and lifted.Further, while a first base is being engaged with a carriage, a secondbase may be engaged with a carriage positioned downstream. Accordingly,rapid and efficient loading of the bases onto the carriages may beachieved.

FIG. 17 illustrates a perspective view of the control component terminalcoupling substation 504. As illustrated, the control component terminalcoupling substation 504 may include a supply unit 802, a first assemblyunit 806 a, and a second assembly unit 806 b. Briefly, the supply unit802 may be configured to provide a plurality of components (e.g., thecontrol component terminals 206). The first assembly unit 806 a and thesecond assembly unit 806 b may each be configured to assemble thecontrol component terminals 206 into cartridges 200 for an aerosoldelivery device 100 by engaging the control component terminals with thebases 204.

In this regard, FIG. 18 illustrates an enlarged view of the supply unit802. As illustrated, the supply unit 802 may be configured to supply aplurality of the control component terminals 206. In some embodimentsthe supply unit 802 may include a vibratory arrangement. For example,the vibratory arrangement may include a vibratory hopper 808, avibratory bowl 810, and a supply track 812. In some embodiments thevibratory hopper 808, the vibratory bowl 810, and/or the supply track812 may be manufactured by Performance Feeders, Inc. of Oldsmar, Fla.

The control component terminals 206 may be loaded into the vibratoryhopper 808. As the vibratory hopper 808 vibrates, the control componentterminals 206 gradually travel under a gate 814 and fall into thevibratory bowl 810 so as to provide the vibratory bowl with asubstantially constant supply of the control component terminals. Inthis regard, a component level sensor 816 may detect a level of thecontrol component terminals 206 within the vibratory bowl 810. Thereby,the vibratory hopper 808 may start and stop based on the level of thecontrol component terminals 206 within the vibratory bowl 810 asdetected by the component level sensor 816. Accordingly, the vibratoryhopper 808 may maintain a substantially constant level of the controlcomponent terminals 206 within the vibratory bowl 810 as the controlcomponent terminals are transported therefrom.

The vibratory bowl 810 may define a pathway 818 configured to arrangethe control component terminals 206 in a serially-aligned stream 820(see, FIG. 20). In this regard, the vibratory motion of the vibratorybowl 810 may direct the control component terminals 206 upwardly alongthe pathway 818, which may narrow such that some control componentterminals fall therefrom and the control component terminals that remainon the pathway become serially-aligned.

As illustrated in FIG. 19, the vibratory bowl 810 may be configured toarrange the control component terminals 206 horizontally, with an upperend 252 of the control component terminal extending outwardly away fromthe vibratory bowl, a lower end 254 of the control component terminalextending inwardly toward the vibratory bowl, and flanges 256 extendingdownwardly into a gap 818 a defined by the pathway 818. However, somecontrol component terminals 206 in the serially-aligned stream 820 maybe oriented upside down or otherwise oriented in a manner that differsfrom the desired orientation. In this regard, as illustrated in FIG. 18,the supply unit 802 may further comprise an actuator 824 configured toindividually remove or realign the control component terminals 206 inthe serially-aligned stream 820 when the control component terminals aremisaligned in a direction. In one embodiment the actuator 824 maycomprise a nozzle 826 configured to direct a flow of air at each controlcomponent terminal 206 that is misaligned to remove the controlcomponent terminal from the pathway 820 or push the control componentterminal into proper alignment. In some embodiments the nozzle 826 maybe oriented so as to only impact those control component terminals 206that are misaligned. In another embodiment the supply unit 802 mayfurther comprise an orientation sensor 822 (e.g., a camera) configuredto determine an alignment of the control component terminals 206 on thepathway 818, and the actuator 824 may be actuated in response theretowhen a misaligned control component terminal is detected.

Accordingly, each of the control component terminals 206 in theserially-aligned stream 820 may be properly oriented downstream of theactuator 824. The control component terminals 206 removed by theactuator 824 may be directed back into the vibratory bowl 810 such thatthe control component terminals may be returned to the pathway 818. Insome embodiments the pathway may define a gap or other featureconfigured to remove the components from the serially-aligned streamwhen the components are misaligned in a second direction. For example,longitudinally oriented control component terminals 206 may fall throughthe gap 818 a in the pathway 818 (see, FIG. 19).

Accordingly, the serially-aligned stream 820 of the control componentterminals 206 may be directed to the supply track 812, which maymaintain the control component terminals in the horizontal orientationand in the single-file arrangement. In some embodiments the supply track812 may comprise a vibratory supply track 812 to facilitate movement ofthe control component terminals 206 therealong. As illustrated in FIG.18, the supply track 812 may include a full sensor 826 configured todetect whether the supply track is full of the control componentterminals 206. In this regard, when the full sensor 826 sense that thesupply track 812 is full, the vibratory bowl 810 may be shut off.Further, the supply track 812 may include a low level sensor 828configured to detect when the supply track is running low on the controlcomponent terminals 206. In this regard, when the low level sensor 828detects a low level of the control component terminals 206 in the supplytrack 812, an indicator 830 (see, FIG. 17) may be illuminated to informan operator that the control component coupling substation 504 isrunning low on the control component terminals, such that the operatormay be informed that it is time to refill the vibratory hopper 808. Insome embodiments the full sensor 826 and the low level sensor 828 maycomprise optical sensors that include an emitter and a receiverconfigured to detect each control component terminal 206 passingthereby.

Further, as illustrated in FIG. 20, the supply unit 802 may include asingulator 832 configured to singulate the control component terminals206 from the serially-aligned stream 820. In this regard, the singulator832 may include a stop 834 that stops the serially-aligned stream 820 ofcontrol component terminals 806 from further advancement. Additionally,the singulator 832 may include a horizontal actuator 836. As illustratedin FIG. 21, the horizontal actuator 836 may be configured tohorizontally displace a terminal plunger 838 to singulate one of thecontrol component terminals 206 from the serially-aligned stream 820. Inone embodiment the terminal plunger 838 may extend under the controlcomponent terminal 206 between the flanges 256 such that the upper end252 of the control component terminal is exposed. Further, a terminalpresence sensor 845 (which may comprise a light emitter and a detector;see, FIG. 20) may detect the presence of the singulated controlcomponent terminal 206. Accordingly, the first assembly unit 806 a maybe prompted to grasp the upper end 252 of the control component terminal206.

In this regard, FIG. 22 illustrates a perspective view of the firstassembly unit 806 a and the second assembly unit 806 b. As illustrated,the first assembly unit 806 a may include a first robotic arm 846 a anda first end effector 848 a coupled thereto. Similarly, the secondassembly unit 806 b may include a second robotic arm 846 b and a secondend effector 848 b coupled thereto.

The first end effector 848 a may be configured to engage the controlcomponent terminal 206. As illustrated in FIG. 23, in some embodimentsthe first end effector 848 a may comprise first and second opposingportions 850, 852 configured to clamp the upper end 252 of the controlcomponent terminal 206 therebetween. Accordingly, the first end effector848 a may be configured to securely grasp each control componentterminal 206.

Further, the first end effector 848 a may be configured to rotatebetween a horizontal configuration employed to grasp and remove thecontrol component terminal 206 from the singulator 832 and a verticalconfiguration (see, FIG. 23) configured to insert the control componentterminal into the first base 204 a. Note that FIG. 22 illustrates thefirst end effector 848 a at an angle between the horizontalconfiguration and the vertical orientation during transitiontherebetween. Accordingly, the first robotic arm 846 a and the first endeffector 848 a may prepare the control component terminal 206 forinsertion into the base 204.

In this regard, a carriage 604 with the first and second bases 204 a,204 b engaged therewith may be directed through the control componentterminal coupling substation 504. As illustrated in FIG. 24, the track602 may direct each carriage 604 through a first processing portion 854a of the first assembly unit 806 a and a second processing portion 854 bof the second assembly unit 806 b at the base load substation 502. Inparticular, each carriage 604 may first be directed through the firstprocessing portion 854 a followed by the second processing portion 854b. Operations relating to the first base 204 a and a first controlcomponent terminal 206 a are conducted at the first processing portion854 a, whereas operations relating to the second base 204 b and a secondcontrol component terminal 206 b (see, FIG. 25) are conducted at thesecond processing portion 854 b.

Accordingly, a carriage 604 may be transported to the first processingportion 854 a along the track 602. The carriage 604 may be directed pasta carriage sensor 856 a, which may comprise a light emitter anddetector, and which detects the presence of the carriage 604. Afterpassing the carriage sensor 856 a, the carriage 604 may be directed pastan initial locator sensor 858 a configured to detect the locator module626 and verify the presence and location of the carriage. An initialstop 860 a may then stop the carriage 604 in the manner described abovewith respect to the initial stop 760 a of the base load substation 502(see, FIG. 15). Thereafter, when any downstream carriage is clear, thecarriage 604 may be released from the initial stop 860 a. Accordingly,the track 602 may move the carriage 604 until the carriage engages alift stop 864 a in the manner described above with respect to the liftstop 764 a of the base load substation 502 (see, FIG. 15). While thecarriage 604 is stopped, a stop locator sensor (not shown; see, e.g.,stop locator sensor 868 b) may detect the locator module 626 and verifythe presence and location of the carriage.

The track 602 may include a lifter mechanism 870 a (see, FIG. 22)configured to lift the carriage 604 after the presence and locationthereof is verified by the stop locator sensor 864 a in the mannerdescribed above with respect to the lifter mechanism 770 a of the baseload substation 502 (see, FIG. 15). While the carriage 604 is lifted andengaged by the lifter mechanism 870 a, the first robotic arm 846 a maydirect the first control component terminal 206 a into engagement withthe first base 204 a. In particular, the lower end 254 of the firstcontrol component terminal 206 a may be engaged with the controlcomponent terminal aperture 250 (see, FIG. 14). At such time, the firstend effector 848 a may release the first control component terminal 206a, such that the first control component terminal may remain inengagement with the first base 204 a. The first robotic arm 846 a maythen return to the singulator 832 to engage an additional controlcomponent terminal for attachment with the first base on a subsequentcarriage.

After the robotic arm 846 a completes the base engagement operation, astorage transceiver 876 a may write code to the storage module 624indicating whether or not the first control component terminal 206 a wasproperly coupled to the first base 204 a. In this regard, a componentpresence sensor 878 a (e.g., comprising a light emitter and receiver)may detect whether the first control component terminal 206 a is engagedwith the first base 204 a following movement of the first robotic arm846 a as described above. For example, the component presence sensor 878a may detect whether or not the first control component terminal 206 ais present while the carriage 604 is lifted by the lifter mechanism 870a. In instances in which the first control component terminal 206 a isnot properly engaged with the first base 204 a, the substationsdownstream of the base load substation 502 may not perform additionaloperations that would be otherwise conducted on the first base 204 a. Inother words, in light of the first control component terminal 206 abeing improperly attached to the base 204 a or missing, the substationsdownstream of the control component terminal coupling substation 504 maynot attempt to couple additional components thereto, so as to avoiddamage to the remaining substations and waste of components. In thissame regard, the storage transceiver 876 a may read the code on thestorage module 624 to determine that the partially-assembled cartridgeis fit for further assembly prior to coupling the control componentterminal 206 a to the base 204 a. Thus, the various storage transceiversdisclosed herein may read the storage module before a particularoperation is performed to determine whether to perform the operation,and write to the storage module after the operation to reflect whetheror not the operation was properly completed.

Thereafter, the lifter mechanism 870 a may release the carriage 604 bylowering the carriage back onto the conveyor belts 628 of the track 602.At such time the carriage 604 may be directed to the second processingportion 854 b by the track 602. The second processing portion 854 b maycomprise the same components included in the first processing portion854 a.

For example, as illustrated in FIG. 24, the second processing portion854 b may include a carriage sensor 856 b, an initial locator sensor 858b, an initial stop 860 b, a lift stop 864 b, a stop locator sensor 868b, and a lifter mechanism 870 b (see, FIG. 22). Accordingly, the secondprocessing portion 854 b may operate in substantially the same manner asthe first processing portion 854 a, and hence the description thereofwill not be repeated. However, as may be understood, the carriage 604may be lifted by the lifter mechanism 870 b such that the second controlcomponent terminal 206 b may be engaged with the second base 204 b, asillustrated in FIG. 25.

After the second robotic arm 846 b completes the control componentterminal engagement operation, a second storage transceiver 876 b maywrite code to the storage module 624 indicating whether or not thesecond control component terminal 206 b was properly engaged with thesecond base 204 b. In this regard, a component presence sensor 878 b(e.g., comprising a light emitter and receiver) may detect whether thesecond control component terminal 206 b is properly engaged with thesecond base 204 b following movement of the second robotic arm 846 b asdescribed above. For example, the component presence sensor 878 b maydetect whether or not the second control component terminal is presentwhile the carriage 604 is lifted by the lifter mechanism 870 b. Ininstances in which the second control component terminal 206 b is notproperly engaged with the second base 204 b additional operations thatwould be otherwise conducted on the second base downstream of the secondrobotic arm 846 b may not be conducted so as to avoid damage to theremaining substations and waste of components. In this same regard, thestorage transceiver 876 b may read the code on the storage module 624 todetermine that the partially-assembled cartridge is fit for furtherassembly prior to coupling the control component terminal 206 b to thebase 204 b.

The lifter mechanism 870 b may then lower such that the track 602transports the carriage 604 including the control component terminals206 a, 206 b respectively coupled to bases 204 a, 204 b downstream.However, as illustrated in FIG. 25, the control component terminals 206a, 206 b may not be fully engaged with the bases 204 a, 204 b by therobotic arms 846 a, 846 b. In this regard, as illustrated in FIG. 26,the control component terminal coupling substation 504 may furthercomprise a third processing portion 854 c. The third processing portion854 c may include a lift stop 864 c, a stop locator sensor 868 c (see,FIG. 22), and a lifter mechanism 870 c. The lift stop 864 c may beconfigured to stop the carriage 604, the stop locator sensor 868 c maybe configured to detect presence of the carriage, and the liftermechanism 870 c may be configured to lift the carriage when detected.

The control component terminal coupling substation 504 may furthercomprise a press 880. The press 880 may be configured to press thecontrol component terminals 206 a, 206 b into full engagement with thebases 204 a, 204 b while the carriage 604 is lifted by the liftermechanism 870 c. In this regard, as a result of the control componentterminals 206 a, 206 b being relatively short, the first and secondassembly units 806 a, 806 b may not be able to fully insert the controlcomponent terminals using the robotic arms 846 a, 846 b and endeffectors 848 a, 848 b, and hence the press 880 may be employed to fullyengage the control component terminals. However, in other embodimentsthe press may not be employed. Following operation of the press 880, astorage transceiver 876 c may write code to the storage module 624indicating whether or not the control component terminals 206 a, 206 bwere properly pressed into the bases 204 a, 204 a (e.g., based oncompletion of a full downward stroke of the press 880).

Note that the above-described operations may be conductedsimultaneously. In this regard, while the first robotic arm 846 acouples the first control component terminal 206 a to the first base 204a, the second robotic arm 846 b may receive the second control componentterminal 206 b from the singulator 832. Conversely, while the secondrobotic arm 846 b couples the second control component terminal 206 b tothe second base 204 b, the first robotic arm 846 a may receive the firstcontrol component terminal 206 a from the singulator 832. Further, thepress 880 may press the control component terminals 206 a, 206 b intofull engagement with the bases 204 a, 204 b while other operations areongoing, such as while the first robotic arm 846 a couples the firstcontrol component terminal 206 a to the first base 204 a and the secondrobotic arm 846 b receives the second control component terminal 206 bfrom the singulator 832. Accordingly, rapid and efficient engagement ofthe control component terminals 206 a, 206 b with the bases 204 a, 204 bmay be achieved.

The negative heating terminal coupling substation 506 and the positiveheating terminal coupling substation 508 may be positioned downstreamfrom the control component terminal coupling substation 504. Forexample, in one embodiment the negative heating terminal couplingsubstation 506 may be positioned downstream from the control componentcoupling substation 506 and the positive heating terminal couplingsubstation 508 may be positioned downstream of the negative heatingterminal coupling substation. The negative heating terminal couplingsubstation 506 and the positive heating terminal coupling substation 508may be substantially similar. In this regard, although the descriptionprovided below is directed to the negative heating terminal couplingsubstation 506, such description is applicable to both the negativeheating terminal coupling substation and the positive heating terminalcoupling substation 508, except as otherwise noted.

FIG. 27 illustrates a perspective view of the negative heating terminalcoupling substation 506. As illustrated, the negative heating terminalcoupling substation 506 may include a supply unit 902, a feeder unit904, a first assembly unit 906 a, and a second assembly unit 906 b.Briefly, the supply unit 902 may be configured to provide a plurality ofcomponents (e.g., the negative heating terminals 234). The feeder unit904 may be configured to receive the negative heating terminals 234 fromthe supply unit and alternatingly feed the negative heating terminals tothe first assembly unit 906 a and the second assembly unit 906 b. Thefirst assembly unit 906 a and the second assembly unit 906 b may each beconfigured to assemble the negative heating terminals 234 intocartridges 200 for an aerosol delivery device 100, for example, byengaging the negative heating terminals with the bases 204.

In this regard, FIG. 28 illustrates an enlarged view of the supply unit902. As illustrated, the supply unit 902 may be configured to supply aplurality of the negative heating terminals 234. In some embodiments thesupply unit 902 may include a vibratory arrangement. For example, thevibratory arrangement may include a vibratory hopper 908, a vibratorybowl 910, and a supply track 912. In some embodiments the vibratoryhopper 908, the vibratory bowl 910, and/or the supply track 912 may bemanufactured by Performance Feeders, Inc. of Oldsmar, Fla.

The negative heating terminals 234 may be loaded into the vibratoryhopper 908. As the vibratory hopper 908 vibrates, the negative heatingterminals 234 gradually travel under a gate 914 and fall into thevibratory bowl 910 so as to provide the vibratory bowl with asubstantially constant supply of the negative heating terminals. In thisregard, a component level sensor 916 may detect a level of the negativeheating terminals 234 within the vibratory bowl 910. Thereby, thevibratory hopper 908 may start and stop based on the level of thenegative heating terminals 234 within the vibratory bowl 910 as detectedby the component level sensor 916. Accordingly, the vibratory hopper 908may maintain a substantially constant level of the negative heatingterminals 234 within the vibratory bowl 910 as the negative heatingterminals are transported therefrom.

The vibratory bowl 910 may define a pathway 918 configured to arrangethe negative heating terminals 234 in a serially-aligned stream 920(see, FIG. 29). In this regard, the vibratory motion of the vibratorybowl 910 may direct the negative heating terminals 234 upwardly alongthe pathway 918, which may narrow such that some negative heatingterminals fall therefrom and the negative heating terminals that remainon the pathway become serially-aligned.

As illustrated in FIG. 29, the vibratory bowl 910 may be configured toarrange the negative heating terminals 234 vertically, with an upper end258 of the negative heating terminal extending downwardly and a lowerend 260 of the negative heating terminal extending upwardly. However,some negative heating terminals 234 in the serially-aligned stream 920may be oriented in a manner that differs from the desired orientation.In this regard, as illustrated in FIG. 28, the supply unit 902 mayfurther comprise an actuator 924 configured to individually remove orrealign the negative heating terminals 234 in the serially-alignedstream 920 when the negative heating terminals are misaligned in adirection. In one embodiment the actuator 924 may comprise a nozzle 926configured to direct a flow of air at each negative heating terminals234 that is misaligned to remove the misaligned negative heatingterminal from the pathway 918 or push the misaligned negative heatingterminal into proper alignment. In some embodiments the nozzle 926 maybe oriented so as to only impact those negative heating terminals 234that are misaligned. In another embodiment the supply unit 902 mayfurther comprise an orientation sensor 922 (e.g., a camera) configuredto determine an alignment of the negative heating terminals 234 on thepathway 918, and the actuator 924 may be actuated in response theretowhen a misaligned negative heating terminal is detected.

Accordingly, each of the negative heating terminals 234 in theserially-aligned stream 920 may be properly oriented downstream of theactuator 924. The negative heating terminals 234 removed by the actuator924 may be directed back into the vibratory bowl 910 such that thenegative heating terminals may be returned to the pathway 918. In someembodiments the pathway may define a gap or other feature configured toremove the components from the serially-aligned stream when thecomponents are misaligned in a second direction.

Accordingly, the serially-aligned stream 920 of the negative heatingterminals 234 may be directed to the supply track 912, which maymaintain the negative heating terminals in the vertical orientation andin the single-file arrangement. In some embodiments the supply track 912may comprise a vibratory supply track to facilitate movement of thenegative heating terminals 234 therealong. As illustrated in FIG. 28,the supply track 912 may include a full sensor 926 configured to detectwhether the supply track is full of the negative heating terminals 234.In this regard, when the full sensor 926 sense that the supply track 912is full, the vibratory bowl 910 may be shut off. Further, the supplytrack 912 may include a low level sensor 928 configured to detect whenthe supply track is running low on the negative heating terminals 234.In this regard, when the low level sensor 928 detects a low level of thenegative heating terminals 234 in the supply track 912, an indicator 930(see, FIG. 27) may be illuminated to inform an operator that thenegative heating terminal coupling substation 506 is running low on thenegative heating terminals, such that the operator may be informed thatit is time to refill the vibratory hopper 908. In some embodiments thefull sensor 926 and the low level sensor 928 may comprise opticalsensors that include an emitter and a receiver configured to detect eachnegative heating terminal 234 passing thereby.

Further, as illustrated in FIG. 29, the supply unit 902 may include asingulator 932 configured to singulate the negative heating terminals234 from the serially-aligned stream 920. In this regard, the singulator932 may include a stop 934 (e.g., comprising a pin) that stops theserially-aligned stream 920 of negative heating terminals 234 fromfurther advancement. As illustrated, in one embodiment a horizontalactuator 936 (see, FIG. 30) may be configured to move the stop 934horizontally between a retracted position and an extended position. Thehorizontal actuator 936 may default to the extended position such thatthe stop 934 blocks the serially-aligned stream 920 of negative heaterterminals 234 from moving. However, the horizontal actuator 936 maymomentarily retract the stop 934 to the retracted position to allow oneof the negative heating terminals 234 to pass the stop. Thereby, asecond stop 938 (e.g., comprising a plate) may stop the outermostnegative heating terminal 234 from further advancement, such that theoutermost negative heating terminal is positioned between the stop 934(i.e., the first stop) and the second stop 938 and singulated from theserially-aligned stream 920.

As illustrated, when the outermost negative heating terminal 234 issingulated between the first stop 934 and the second stop 938, a biasingmember 940 may engage the outermost negative heating terminal 234 suchthat the outermost negative heating terminal 234 is further separatedfrom the remaining negative heating terminals. In particular, thebiasing member 940 may be configured to extend upwardly to engage thedownwardly-extending upper end 258 of the outermost negative heatingterminal 234. In this regard, the biasing member 940 may define anangled surface 942 that engages and presses outwardly on the upper end258 of the outermost negative heating terminal 234 as the biasing member940 extends upward.

After the outermost negative heating terminal 234 is singulated, thisnegative heating terminal may be transferred to the feeder unit 904.FIG. 30 illustrates a perspective view of the feeder unit 904. In someembodiments the feeder unit 904 may comprise a rotary member 944. Therotary member 944 may include a first engagement head 946 a and a secondengagement head 946 b respectively configured to receive one of thenegative heating terminals 234 from the supply unit 902. In this regard,the first engagement head 946 a may define a first gripper 948 a and thesecond engagement head 946 b may define a second gripper 948 b. Asillustrated, in some embodiments the rotary member 944 may comprise afirst arm 950 a and a second arm 950 b. The first engagement head 946 amay be coupled to the first arm 950 a and the second engagement head 946b may be coupled to the second arm 950 b.

The rotary member 944 may be configured to swivel between a firstreceiving position at which the first engagement head 946 a ispositioned proximate the feeder 902 and a second receiving position(see, FIGS. 29 and 30) in which the second engagement head 946 b ispositioned proximate the feeder. Thereby, a first negative heatingterminal 234 a singulated from the serially-aligned stream 920 may begrasped by the first gripper 948 a of the first engagement head 946 a inthe first receiving position. In this regard, a terminal singulationsensor 952 (e.g., an optical sensor; see FIG. 29) may detect that anegative heating terminal 234 has been singulated.

A first gripper extender 954 a may then extend the first gripper 948 a,which is open, around the first negative heating terminal 234 a. Thefirst gripper 948 a may then shut so as to clamp onto the first heatingterminal 234 a. A second horizontal actuator 956 (see, FIG. 29) may thenretract the second stop 938 such that the first gripper extender 954 amay retract the first gripper 948 a with the first negative heatingterminal 234 a engaged therewith.

A terminal load sensor 958 (e.g., an optical sensor) may detect whetherthe first gripper 948 a properly gripped the first heating terminal 234a. The rotary member 944 may then swivel to a first delivery position(e.g., by rotating clockwise when viewed from above) to a first deliveryposition, which corresponds to the second receiving position, and whichis illustrated in FIG. 30.

FIG. 31 illustrates the first assembly unit 906 a and the secondassembly unit 906 b. As illustrated, the first assembly unit 906 a mayinclude a first robotic arm 960 a and a first end effector 962 a coupledthereto. Similarly, the second assembly unit 906 b may include a secondrobotic arm 960 b and a second end effector 962 b coupled thereto.

The first end effector 962 a may be configured to engage the firstnegative heating terminal 234 a and deliver the first negative heatingterminal to the first base 204 a on a carriage 604 on the track 602 viamovement of the first robotic arm 960 a. Thus, the first assembly unit906 a may be positioned such that the first robotic arm 960 a isconfigured to move the first end effector 962 a between the feeder unit904 and the track 602. In this regard, when the rotary member 944 is inthe first delivery position (see, FIGS. 29-31), the first robotic arm960 a may direct the first end effector 962 a into proximity with thefirst negative heating terminal 234 a held by the first gripper 948 a ofthe feeder unit 904.

Accordingly, the first end effector 962 may be configured to engage thefirst negative heating terminal 234 a. As illustrated in FIG. 32, insome embodiments the first end effector 962 a may comprise first andsecond opposing portions 964, 966 configured to clamp the first negativeheating terminal 234 a therebetween. Accordingly, the first end effector962 a may be configured to securely grasp each first negative heatingterminal 234 a.

As described above, the singulator 932 may supply the first negativeheating terminals 234 a upside down, with the upper end 258 thereofpointing downwardly, and this orientation may be maintained by thesupply unit 904, such that the first end effector 962 a receives thefirst negative heating terminals in this inverted orientation. Inparticular, the first end effector 962 a may grasp each first negativeheating terminal 234 a between the upper end 258 and the lower end 260,substantially at a middle thereof. The first end effector 962 a maythereby rotate one hundred eighty degrees such that the lower end 260 ofthe first negative heating terminal 234 a is pointed downwardly, asillustrated in FIG. 33.

Accordingly, the track 602 may move the carriage 604 such that the firstbase 204 a is positioned for receipt of the first negative heatingterminal 234 a. In this regard, a carriage 604 with the first and secondbases 204 a, 204 b engaged therewith, and the control componentterminals 206 a, 206 b engaged with the bases may be directed throughthe negative heating terminal coupling substation 506. As illustrated inFIG. 34, the track 602 may direct each carriage 604 through a firstprocessing portion 968 a of the first assembly unit 906 a and a secondprocessing portion 968 b of the second assembly unit 906 b at thenegative heating terminal coupling substation 506. In particular, eachcarriage 604 may first be directed through the first processing portion968 a followed by the second processing portion 968 b. Operationsrelating to the first base 204 a and the first negative heatingterminals 234 a are conducted at the first processing portion 968 a,whereas operations relating to the second base 204 b and the secondnegative heating terminals 234 b (see, e.g., FIG. 30) are conducted atthe second processing portion 968 b.

Accordingly, a carriage 604 may be transported along the track 602 tothe first processing portion 968 a. The carriage 604 may be directedpast a carriage sensor 970 a, which may comprise a light emitter anddetector, and which detects presence of the carriage 604. After passingthe carriage sensor 970 a, the carriage 604 may be directed past aninitial locator sensor 972 a configured to detect the locator module 626and verify the presence and location of the carriage. An initial stop974 a may then stop the carriage 604 in the manner described above withrespect to the initial stop 760 a of the base load substation 502 (see,FIG. 15). Thereafter, when any downstream carriage is clear, thecarriage 604 may be released from the initial stop 974 a. Accordingly,the track 602 may move the carriage 604 until the carriage engages alift stop 976 a in the manner described above with respect to the liftstop 764 a of the base load substation 502 (see, FIG. 15). While thecarriage 604 is stopped, a stop locator sensor 978 a may detect thelocator module 626 and verify the presence and location of the carriage.

The track 602 may include a lifter mechanism 980 a configured to liftthe carriage 604 after the presence and location thereof is verified bythe stop locator sensor 978 a in the manner described above with respectto the lifter mechanism 770 a of the base load substation 502 (see, FIG.15). While the carriage 604 is lifted and engaged by the liftermechanism 980 a, the first robotic arm 960 a may lower the first endeffector 962 a such that the lower end 260 of the first negative heatingterminal 234 a extends into the negative heating terminal aperture 248 a(see, FIG. 14).

In some embodiments the first assembly unit 906 a may include a firstpusher 982 a positioned proximate the first end effector 962 a. Asillustrated in FIG. 32, the first pusher 982 a may be configured toextend downwardly to press against the first negative heating terminal234 a to fully insert the first negative heating terminal into the firstbase 204 a. Prior to the first pusher 982 a extending, the first endeffector 962 a may release the first negative heating terminal 234 a,such that the first negative heating terminal may remain in engagementwith the first base 204. The first robotic arm 960 a may then return tothe singulator 932 to engage an additional negative heating terminal forattachment with the first base on a subsequent carriage.

After the robotic arm 960 a engages the first negative heating terminal234 a with the first base 204 a, a storage transceiver (not shown; see,e.g., storage transceiver 984 b) may write code to the storage module624 indicating whether or not the first negative heating terminal 234 awas properly coupled to the first base 204 a. In this regard, acomponent presence sensor 986 a (e.g., comprising a light emitter andreceiver) may detect whether the first negative heating terminal 234 ais engaged with the first base 204 a following movement of the firstrobotic arm 960 a as described above. For example, the componentpresence sensor 986 a may detect whether or not the first negativeheating terminal 234 a is present while the carriage 604 is lifted bythe lifter mechanism 980 a. In instances in which the first negativeheating terminal 234 a is not properly engaged with the first base 204a, the substations downstream of the base load substation 502 may notperform additional operations that would be otherwise conducted on thefirst base 204 a. In other words, in light of the first negative heatingterminal 234 a being improperly attached to the base 204 a or missing,the substations downstream of the negative heating terminal couplingsubstation 506 may not attempt to couple additional components thereto,so as to avoid damage to the remaining substations and waste ofcomponents. In this same regard, the storage transceiver may read thecode on the storage module 624 to determine that the partially-assembledcartridge is fit for further assembly prior to coupling the negativeheating terminal 234 a to the base 204 a.

Thereafter, the lifter mechanism 980 a may release the carriage 604 bylowering the carriage back onto the conveyor belts 628. At such time thecarriage 604 may be directed along the track 602 to the secondprocessing portion 968 b. The second processing portion 968 b maycomprise the same components included in the first processing portion968 a. For example, as illustrated in FIG. 34, the second processingportion 968 b may include a carriage sensor 970 b, an initial locatorsensor 972 b, an initial stop 974 b, a lift stop 976 b, a stop locatorsensor 978 b, and a lifter mechanism 980 b. Accordingly, the secondprocessing portion 968 b may operate in substantially the same manner asthe first processing portion 968 a, and hence the description thereofwill not be repeated. However, as may be understood, the carriage 604may be lifted by the lifter mechanism 980 b such that the secondnegative heating terminal 234 b may be engaged with the second base 204b.

In this regard, while the first negative heating terminal 234 a isdelivered to the first assembly unit 906 a for insertion in the firstbase 204 a, the second negative heating terminal 234 b may be singulatedfrom the serially-aligned stream 920 of negative heating terminals. Inparticular, with reference to FIGS. 29 and 30, the second horizontalactuator 956 may extend the second stop 938 to the default extendedconfiguration, the biasing member 940 may retract, and the horizontalactuator 936 (i.e., the first horizontal actuator) may retract the firststop 934 such that a negative heating terminal 234 (i.e., the secondnegative heating terminal 234 b) advances to the second stop 938. Thefirst horizontal actuator 936 may then extend the first stop 934 suchthat the second negative heating terminal 234 b is received between thefirst stop 934 and the second stop 938. The biasing member 940 may thenextend to separate the second heating terminal 234 b from theserially-aligned stream 920 of negative heating terminals.

Accordingly, the second gripper 948 b of the feeder unit 904 may engagethe second negative heating terminal 234 b. Thereby, the feeder unit 904may swivel (e.g., by rotating counterclockwise when viewed from above),and position the second negative heating terminal 234 b proximate thetrack 602. The second robotic arm 960 b, the second end effector 962 b,and a second pusher (not shown; see, e.g., pusher 982 a) may then engagethe second negative heating terminal 234 b in the negative heatingterminal aperture 248 b of the second base 204 b in the manner describedabove.

After the second robotic arm 960 b completes the second negative heatingterminal engagement operation, the second storage transceiver 984 b maywrite code to the storage module 624 indicating whether or not thesecond negative heating terminal 234 b was properly engaged with thesecond base 204 b. In this regard, a component presence sensor 986 b(e.g., comprising a light emitter and receiver) may detect whether thesecond negative heating terminal 234 b is properly engaged with thesecond base 204 b following movement of the second robotic arm 960 b asdescribed above. For example, the component presence sensor 986 b maydetect whether or not the second negative heating terminal 234 b ispresent while the carriage 604 is lifted by the lifter mechanism 980 b.In instances in which the second negative heating terminals 234 b is notproperly engaged with the second base 204 b additional operations thatwould be otherwise conducted on the second base downstream of the secondrobotic arm 960 b may not be conducted so as to avoid damage to theremaining substations and waste of components. Following attachment ofthe second negative heating terminal 234 b and detection of presence orabsence thereof, the lifter mechanism 980 b may lower the carriage 604such that the track 602 transports the carriage including the negativeheating terminals 234 a, 234 b respectively coupled to bases 204 a, 204b downstream. In this same regard, the storage transceiver 984 b mayread the code on the storage module 624 to determine that thepartially-assembled cartridge is fit for further assembly prior tocoupling the negative heating terminal 234 b to the base 204 b.

Note that the above-described operations may be conductedsimultaneously. In this regard, while the first engagement head 946 adelivers the first negative heating terminal 234 a to the first roboticarm 960 a, the second engagement head 946 b may receive the secondnegative heating terminal 234 b from the singulator 932. Conversely,while the second engagement head 946 b delivers the second negativeheating terminal 234 b to the second robotic arm 960 b, the firstengagement head 946 a may receive the first negative heating terminal234 a from the singulator 932. Further, while the first robotic arm 960a couples the first negative heating terminal 234 a to the first base204 a, the second robotic arm 960 b may receive the second negativeheating terminal 234 b from the rotary member 944. Conversely, while thesecond robotic arm 960 b couples the second negative heating terminals235 to the second base 204 b, the first robotic arm 960 a may receivethe first negative heating terminal 234 a from the rotary member 944.Accordingly, rapid and efficient engagement of the negative heatingterminals 234 a, 234 b with the bases 204 a, 204 b may be achieved.

As noted above, the positive heating terminal coupling substation 508may be substantially similar to the negative heating terminal couplingsubstation 506. Accordingly, a description of the various components ofthe positive heating terminal coupling substation 508 will not berepeated. However, in some embodiments the positive heating terminalcoupling substation 508 may additionally include an inspection unit 988,which may be positioned downstream of the first and second assemblyunits thereof, which may be substantially similar to the first andsecond assembly units 906 a, 906 b of the negative heating terminalcoupling substation 506, as noted above.

As illustrated in FIG. 35, the inspection unit 988 may include aninspection locator sensor 990, which may detect the presence of thecarriage 604. A first inspection stop 992 may momentarily stop thecarriage at a location at which the first base 204 a is positionedproximate an imaging device 994 (e.g., a digital camera). Accordingly,the imaging device 994 may capture an image of the first controlcomponent terminal 206 a, the first negative heating terminal 234 a, anda first positive heating terminal (see, e.g., positive heating terminal235 in FIG. 1). Following release from the first inspection stop 992,the carriage 604 may travel downstream on the track 602 and engage asecond inspection stop 996, at which the second base 204 b is positionedproximate the imaging device 994. Accordingly, the imaging device 994may capture an image of the second control component terminal 206 b, thesecond negative heating terminal 234 b, and a second positive heatingterminal (see, e.g., positive heating terminal 235 in FIG. 1).

In some embodiments a backlight 998 may be positioned across from theimaging device 994, such that the terminals 206, 234, 235 are positionedbetween the imaging device and the backlight, to improve imaging of theterminals. Accordingly, the images captured by the imaging device 994may be analyzed to determine whether the terminals 206, 234, 235 aremissing or improperly engaged with the bases 204. For example, theheight to which the terminals 206, 234, 235 extend from the base 204 maybe determined and compared to a desired height of the terminals. A thirdstorage transceiver 984 c may write code to the storage module 624indicating whether or not the terminals 206, 234, 235 are properlyengaged with the bases 204. In instances in which the terminals 206,234, 235 are not properly engaged with the bases 204, additionaloperations that would be otherwise conducted thereon downstream of thepositive heating terminal coupling substation 508 may not be conductedso as to avoid damage to the remaining substations and waste ofcomponents.

The control component coupling substation 510 may be positioneddownstream of the positive heating terminal coupling substation 508.FIG. 36 illustrates a perspective view of the control component couplingsubstation 510. As illustrated, the control component couplingsubstation 510 may include a supply unit 1002, a feeder unit 1004, afirst assembly unit 1006 a, and a second assembly unit 1006 b. Briefly,the supply unit 1002 may be configured to provide a plurality ofcomponents (in particular, electronic control components 208). Thefeeder unit 1004 may be configured to receive the electronic controlcomponents 208 from the supply unit and alternatingly feed theelectronic control components 208 to the first assembly unit 1006 a andthe second assembly unit 1006 b. The first assembly unit 1006 a and thesecond assembly unit 1006 b may each be configured to assemble theelectronic control components 208 into cartridges 200 for an aerosoldelivery device 100 (e.g., by engaging the electronic control componentswith the control component terminals 206).

In this regard, FIG. 37 illustrates an enlarged view of the supply unit1002. As illustrated, the supply unit 1002 may be configured to supply aplurality of the electronic control components 208. In some embodimentsthe supply unit 1002 may include a vibratory arrangement. For example,the vibratory arrangement may include a vibratory bowl 1010 and a supplytrack 1012. In some embodiments the vibratory bowl 1010 and/or thesupply track 1012 may be manufactured by Performance Feeders, Inc. ofOldsmar, Fla. Further, in some embodiments the vibratory bowl 1010and/or various other components of the control component couplingsubstation 510 may be coated with an antistatic coating configured toavoid damaging the electronic control components 208, which may includea circuit board.

The electronic control components 208 may be loaded directly into thevibratory bowl 1010, or a vibratory hopper may supply the electroniccontrol components 208 to the vibratory bowl in the manner describedabove. The vibratory bowl 1010 may define a pathway 1018 configured toarrange the electronic control components 208 in a serially-alignedstream 1020. In this regard, the vibratory motion of the vibratory bowl1010 may direct the electronic control components 208 upwardly along thepathway 1018, which may narrow such that some electronic controlcomponents fall therefrom and the electronic control components thatremain on the pathway become serially-aligned.

The vibratory bowl 1010 may be configured to arrange the electroniccontrol components 208 generally horizontally with longitudinal endsthereof contacting one-another. However, some electronic controlcomponents 208 in the serially-aligned stream 1020 may be oriented in amanner that differs from the desired orientation. In this regard, asillustrated in FIG. 38, the supply unit 1002 may further comprise anactuator 1024 configured to individually remove or realign theelectronic control components 208 in the serially-aligned stream 1020when the electronic control components are misaligned in a direction. Inone embodiment the actuator 1024 may comprise a nozzle 1026 configuredto direct a flow of air at each electronic control components 208 thatis misaligned to remove the electronic control component from thepathway 1020 or push the electronic control component into properalignment. In some embodiments the nozzle 1026 may be oriented so as toonly impact those electronic control components 208 that are misalignedwith a flow of air directed therefrom.

In another embodiment the supply unit 1002 may further comprise anorientation sensor 1028 (e.g., a camera) configured to determine analignment of the electronic control components 208 on the pathway 1018,and the actuator 1024 may be actuated in response thereto when amisaligned electronic control component is detected. For example asillustrated in FIG. 39, each of the electronic control components 208may define a first longitudinal end 262 and a second longitudinal end264. The first longitudinal end 262 may be oriented downstream of thesecond longitudinal end 264 in a proper orientation for performance ofadditional operations on the electronic control component 208 asdescribed hereinafter. Accordingly, electronic control componentsdefining a different orientation, as detected by the orientation sensor1028, may be removed from the pathway 1018 by the nozzle 1026.

In some embodiments the electronic control components 208 may also beasymmetrical with respect to a first major surface 266 and a secondmajor surface 268. For example, as illustrated in FIG. 39, the firstmajor surface 266 of the electronic control components 208 may include achip (e.g., a memory chip) extending therefrom. Further, the opposingsecond major surface 268 of the electronic control components 208 may besubstantially flat. Accordingly, the orientation sensor 1028 mayadditionally determine which major side of the electronic controlcomponents 208 is oriented away from the vibratory bowl 1010, and anyelectronic control components oriented differently from a desiredorientation (e.g., an orientation in which the first major surface 266faces away from the vibratory bowl) may be removed from the pathway 1018by the nozzle 1026.

Alternatively or additionally, as illustrated in FIG. 39, in someembodiments the pathway 1018 may define a gap 1030 or other featureconfigured to remove the electronic control components 208 from theserially-aligned stream 1020 when the electronic control components aremisaligned in a second direction. For example, as noted above, the firstand second major surfaces 266, 268 of the electronic control components208 may be asymmetrical. In this regard, the first major surface 266 ofthe electronic control component 208 may include a memory chip or otherfeature defining a protrusion extending along a portion of thelongitudinal length of the electronic control component. Thereby, whenthe electronic control component 208 is oriented with the first majorsurfaces 268 of the electronic control component toward the vibratorybowl 1010, the protrusion may enter the gap 1030. Thereby, the gap 1030may be configured to cause the electronic control component terminals208 to fall from the pathway 1018 when the major surfaces thereof areoppositely oriented relative to a desired orientation. In someembodiments the gap 1030 may be positioned upstream from the actuator1024 so as to allow the actuator to only remove those electronic controlcomponents that are longitudinally improperly oriented.

Accordingly, each of the electronic control components 208 in theserially-aligned stream 1020 may be properly oriented downstream of thegap 1030 and the actuator 1024. The electronic control components 208removed by the gap 1030 and the actuator 1024 may be directed back intothe vibratory bowl 1010 such that the electronic control components maybe returned to the pathway 1018. Thus, the removed electronic controlcomponents 208 may be directed back into the serially-aligned stream1020.

Thereby the serially-aligned stream 1020 of the electronic controlcomponents 208 may be directed to the supply track 1012, which maymaintain the electronic control components in the horizontal orientationand in the longitudinal single-file arrangement. In some embodiments thesupply track 1012 may comprise a vibratory supply track to facilitatemovement of the electronic control components 208 therealong. Asillustrated in FIG. 37, the supply track 1012 may include a full sensor1032 configured to detect whether the supply track is full of theelectronic control components 208. In this regard, when the full sensor1032 senses that the supply track 1012 is full, the vibratory bowl 1010may be shut off. Further, the supply track 1012 may include a low levelsensor 1034 configured to detect when the supply track is running low onthe electronic control components 208. In this regard, when the lowlevel sensor 1034 detects a low level of the electronic controlcomponents 208 in the supply track 1012, an indicator 1030 (see, FIG.36) may be illuminated to inform an operator that the electronic controlcomponent coupling substation 510 is running low on the electroniccontrol components, such that the operator may be informed that it istime to refill the vibratory bowl 1010. In some embodiments the fullsensor 1032 and the low level sensor 1034 may comprise optical sensorsthat include an emitter and a receiver configured to detect the presenceor absence of electronic control components 208 positioned therebetween.

Further, as illustrated in FIG. 40, the supply unit 1002 may include asingulator 1036 configured to singulate the electronic controlcomponents 208 from the serially-aligned stream 1020. In this regard,the singulator 1036 may include a stop 1038 (e.g., comprising a pin)that stops the serially-aligned stream 1020 of electronic controlcomponents 208 from further advancement. As illustrated, in oneembodiment a vertical actuator 1040 may be configured to move the stop1038 vertically between a retracted position and an extended position.The vertical actuator 1040 may default to the extended position suchthat the stop 1038 blocks the serially-aligned stream 1020 of electroniccontrol components 208 from moving. However, the vertical actuator 1040may momentarily retract the stop 1038 to the retracted position to allowone of the electronic control components 208 to pass the stop. Thereby,an outermost electronic control component 208 may be directed to thefeeder unit 1004. Further, the vertical actuator 1040 may move the stop1038 to the extended position after the outermost electronic controlcomponent 208 passes thereunder such that an electronic controlcomponent is singulated from the serially-aligned stream 1020, andreceived by the feeder unit 1004.

FIG. 40 further illustrates a perspective view of the feeder unit 1004.In some embodiments the feeder unit 1004 may comprise a rotary member1042. The rotary member 1042 may include a first engagement head 1044 aand a second engagement head 1044 b respectively configured to receiveone of the electronic control components 208 from the supply unit 1002.In this regard, the first engagement head 1044 a may define a firstpocket 1046 a and the second engagement head 1044 b may define a secondpocket 1046 b. As illustrated, in some embodiments the rotary member1042 may comprise a first arm 1048 a and a second arm 1048 b. The firstengagement head 1044 a may be coupled to the first arm 1048 a and thesecond engagement head 1044 b may be coupled to the second arm 1048 b.

FIG. 40 illustrates the rotary member 1042 in a first receiving positionand FIG. 41 illustrates the rotary member in a second receivingposition, between which the rotary member may be configured to swivel.In the first receiving position, the first engagement head 1044 a ispositioned proximate the singulator 1036. Thereby, a first electroniccontrol component 208 a may be singulated from the serially-alignedstream 1020 and delivered into the first pocket 1046 a in the firstengagement head 1044 a. A singulation sensor 1050 (e.g., an opticalsensor) may detect that the first electronic control component 208 a hasbeen singulated and delivered to the first engagement head 1044 a.

After the first electronic control component 208 a is received in thefirst engagement head 1044 a, the rotary member 1042 may swivel (e.g.,by rotating clockwise when viewed from above) to a first deliveryposition, which corresponds to the second receiving position, and whichis illustrated in FIG. 41. As the rotary member 1042 swivels, negativepressure may be applied to the first pocket 1046 a. Thereby, thenegative pressure may assist in retaining the first electronic controlcomponent 208 a on the rotary member 1042 during swiveling movementthereof. Accordingly, the first electronic control component 208 a maybe moved to the first delivery position.

FIG. 42 illustrates the first assembly unit 1006 a and the secondassembly unit 1006 b. As illustrated, the first assembly unit 1006 a mayinclude a first robotic arm 1052 a and a first end effector 1054 acoupled thereto. Similarly, the second assembly unit 1006 a may includea second robotic arm 1052 b and a second end effector 1054 b coupledthereto.

The first end effector 1054 b may be configured to engage the firstelectronic control component 208 a and deliver the first electroniccontrol component to the first base 204 a, which is engaged with acarriage 604 on the track 602, via movement of the first robotic arm1052 a. Thus, the first assembly unit 1006 a may be positioned such thatthe first robotic arm 1052 a is configured to move the first endeffector 1054 a between the feeder unit 1004 and the track 602. In thisregard, when the rotary member 1042 is in the first delivery position(see, FIG. 41), the first robotic arm 1052 a may direct the first endeffector 1054 a into proximity with the first electronic controlcomponent 208 a held by the first engagement head 1044 a of the feederunit 1004.

Accordingly, the first end effector 1054 a may be configured to engagethe first electronic control component 208 a. As illustrated in FIGS. 43and 44, in some embodiments the first end effector 1054 a may comprisefirst and second opposing portions 1056, 1058 configured to clamp thefirst electronic control component 208 a therebetween. Accordingly, thefirst and second opposing portions 1056, 1058 of the first end effector1048 a may securely grasp the first electronic control component 208 aand the first robotic arm 1052 a may lift the first electronic controlcomponent from the rotary member 1042. In some embodiments the firstpocket 1046 a may stop applying negative pressure while the firstassembly unit 1006 a lifts the first electronic control component 208 atherefrom.

Accordingly, the track 602 may move the carriage 604 such that the firstbase 204 a is positioned for receipt of the first electronic controlcomponent 208 a. In this regard, a carriage 604 with the bases 204engaged therewith, and the negative heating terminal 234, the positiveheating terminal 235, and the control component terminal 206 engagedwith the bases, may be directed through the control component couplingsubstation 510. As illustrated in FIG. 45, the track 602 may direct eachcarriage 604 through a first processing portion 1060 a of the firstassembly unit 1006 a and a second processing portion 1060 b of thesecond assembly unit 106 b at the control component coupling substation510. In particular, each carriage 604 may first be directed through thefirst processing portion 1060 a followed by the second processingportion 1060 b. Operations relating to the first base 204 a and thefirst electronic control component 208 a are conducted at the firstprocessing portion 1060 a, whereas operations relating to the secondbase 204 b and the second electronic control component 208 b (see, FIG.40) are conducted at the second processing portion 1060 b.

Accordingly, a carriage 604 may be transported along the track 502 tothe first processing portion 1060 a. The carriage 604 may be directedpast a carriage sensor 1062 a, which may comprise a light emitter anddetector, and which detects the presence of the carriage 604. Afterpassing the carriage sensor 1062 a, the carriage 604 may be directedpast an initial locator sensor 1064 a configured to detect the locatormodule 626 and verify the presence and location of the carriage. Aninitial stop 1066 a may then stop the carriage 604 in the mannerdescribed above with respect to the initial stop 760 a of the base loadsubstation 502 (see, FIG. 15). Thereafter, when any downstream carriageis clear, the carriage 604 may be released from the initial stop 1066 a.Accordingly, the track 602 may move the carriage 604 until the carriageengages a lift stop 1068 a in the manner described above with respect tothe lift stop 764 a of the base load substation 502 (see, FIG. 15).While the carriage 604 is stopped, a stop locator sensor 1070 a maydetect the locator module 626 and verify the presence and location ofthe carriage.

The track 602 may include a lifter mechanism 1072 a configured to liftthe carriage 604 after the presence and location thereof is verified bythe stop locator sensor in the manner described above with respect tothe lifter mechanism 770 a of the base load substation 502 (see, FIG.15). While the carriage 604 is lifted and engaged by the liftermechanism 1072 a, the first robotic arm 1052 a may lower the first endeffector 1054 a such that the first end 262 of the first electroniccontrol component 208 a engages the first control component terminal 206a.

In this regard, as illustrated in FIGS. 43 and 44, the first endeffector 1054 a may further comprise a pivoting gripper 1074 a. Thepivoting gripper 1074 a may be configured to apply a negative pressureto the first electronic control component 208 a. Accordingly, when thefirst and second opposing portions 1056, 1058 release, the pivotinggripper 1074 a may remain in engagement with the first electroniccontrol component 208 a.

As illustrated in FIGS. 43 and 44, the pivoting gripper 1074 a may beconfigured to pivot downwardly, such that the first electronic controlcomponent 208 a transitions from a substantially horizontalconfiguration to a substantially vertical configuration. Thereby, thefirst electronic control component 208 a may be positioned between thenegative heating terminal 234 and the positive heating terminal 235 incontact with the control component terminal 206. In some embodiments theassembly units 1006 a, 1006 b may respectively include a terminalspreader 1076 a, 1076 b (see, FIG. 45), which may be configured tospread the negative heating terminal 234 and the positive heatingterminal 235 apart from one another in order to facilitate insertion ofthe electronic control component 208 therebetween.

After the electronic control component 208 is engaged with the controlcomponent terminal 206, the pivoting gripper 1074 a may stop applyingthe negative pressure to the first electronic control component 208 a,such that the first electronic control component remains in engagementwith the control component terminal 206 a between the negative andpositive heating terminals 234 a, 235 a. The first robotic arm 1052 amay then return to the feeder unit 1004 to engage an additional firstelectronic control component for attachment with the first base 204 a ona subsequent carriage 604.

After the robotic arm 1060 a engages the first electronic controlcomponent 208 a with the first base 204 a (e.g., via the controlcomponent terminal 206), a storage transceiver 1078 a may write code tothe storage module 624 indicating whether or not the first electroniccontrol component 208 a was properly coupled to the first base 204 a. Inthis regard, for example, the storage transceiver 1078 a may storeinformation to the storage module 624 indicating that the electroniccontrol component 208 a is improperly attached unless each of themovements of the components of the first assembly unit 1006 a aresuccessfully completed, as detected by various motion sensors associatedtherewith. In instances in which the first electronic control component208 a is deemed to not be properly engaged with the first base 204 a,the substations downstream of the control component coupling substation510 may not perform additional operations that would be otherwiseconducted on the first base 204 a. In other words, in light of the firstelectronic control component 208 a being improperly attached to the base204 a or missing, the substations downstream of the electronic controlcomponent coupling substation 510 may not attempt to couple additionalcomponents thereto, so as to avoid damage to the remaining substationsand waste of components. In this same regard, the storage transceiver1078 a may read the code on the storage module 624 to determine that thepartially-assembled cartridge is fit for further assembly prior tocoupling the electronic control component 208 a to the control componentterminal 206 coupled to the first base 204 a.

Thereafter, the lifter mechanism 1072 a may release the carriage 604 bylowering the carriage back onto the conveyor belts 628. At such time thecarriage 604 may be directed along the track 602 to the secondprocessing portion 1060 b. As illustrated in FIG. 46, the secondprocessing portion 1060 b may comprise the same components included inthe first processing portion 1060 a. For example, the second processingportion 1060 b may include a carriage sensor 1062 b (see, FIG. 42), aninitial locator sensor 1064 b, an initial stop 1066 b, a lift stop 1068b, a stop locator sensor 1070 b, a lifter mechanism 1072 b, and astorage transceiver 1078 b. Accordingly, the second processing portion1060 b may operate in substantially the same manner as the firstprocessing portion 1068 a, and hence the description thereof will not berepeated.

In this regard, while the first electronic control component 208 a isdelivered to the first assembly unit 1006 a for engagement with thefirst base 204 a, the second electronic control component 208 b may besingulated from the serially-aligned stream 1020 of electronic controlcomponents in the manner described above and received in the secondpocket 1046 b in the second engagement head 1044 b, as illustrated inFIG. 41. Thereby, when the rotary member 1042 swivels back to the firstreceiving position, as illustrated in FIG. 40, the second electroniccontrol component 208 b may be received by the second assembly unit 1006b, which may then engage the second electronic control component 208 bwith the second base 204 b in the manner described above.

After the second electronic control component 208 b is coupled to thesecond base 208 b, the lifter mechanism 1072 b may lower the carriage604 such that the track 602 transports the carriage downstream. Asillustrated, in FIG. 46, an inspection unit 1080 may be positioneddownstream of the second assembly unit 1006 b. The inspection unit 1080may include an inspection locator sensor 1082, which may detect thepresence of the carriage 604. A lift stop 1084 may momentarily stop thecarriage 604 at a location at which a lifter mechanism 1086 may lift thecarriage 604 after the carriage is detected by the inspection locatorsensor 1082. Accordingly, first and second component presence sensors1088 a, 1088 b (e.g., comprising a light emitter and a receiver) maydetect the presence of the electronic control components 208 a, 208 b.Accordingly, a storage transceiver 1090 may write code to the storagemodule 624 indicating whether or not the electronic control components208 a, 208 b are properly attached to a respective base 204 a, 204 b. Ininstances in which the electronic control components 208 a, 208 b arenot properly engaged with a respective base 204 a, 204 b, thesubstations downstream of the control component coupling substation 510may not perform additional operations that would be otherwise conductedon the base. The lifter mechanism 1086 may lower the carriage 604 suchthat the track 602 transports the carriage including the positive andnegative heating terminals 234, 235, the control component terminal 206,and the electronic control component 208 respectively coupled to bases204 a, 204 b downstream.

Note that the above-described operations may be conductedsimultaneously. In this regard, while the first engagement head 1044 adelivers the first electronic control component 208 a to the firstrobotic arm 1052 a, the second engagement head 1044 b may receive thesecond electronic control component 208 b from the singulator 1036.Conversely, while the second engagement head 1044 b delivers the secondelectronic control component 208 b to the second robotic arm 1052 b, thefirst engagement head 1044 a may receive the first electronic controlcomponent 208 a from the singulator 1036. Further, while the firstrobotic arm 1052 a couples the first electronic control component 208 ato the first base 204 a, the second robotic arm 1052 b may receive thesecond electronic control component 208 b from the second engagementhead 1044 a. Conversely, while the second robotic arm 1052 b couples thesecond electronic control components 208 b to the second base 204 b, thefirst robotic arm 1052 a may receive the first electronic controlcomponents 208 a from the first engagement head 1044 a. Accordingly,rapid and efficient engagement of the electronic control components 208a, 208 b with the bases 204 a, 204 b may be achieved.

The flow director coupling substation 512 may be positioned downstreamof the control component coupling substation 510. FIG. 47 illustrates aperspective view of the flow director coupling substation 512. Asillustrated, the flow director coupling substation 512 may include asupply unit 1102, a feeder unit 1104, a first assembly unit 1106 a, anda second assembly unit 1106 b. Briefly, the supply unit 1102 may beconfigured to provide a plurality of components (in particular, flowdirectors 210). The feeder unit 1104 may be configured to receive theflow directors 210 from the supply unit 1102 and alternatingly feed theflow directors to the first assembly unit 1106 a and the second assemblyunit 1106 b. The first assembly unit 1106 a and the second assembly unit1106 b may each be configured to assemble the flow directors 210 intocartridges 200 for an aerosol delivery device 100, for example bypositioning the flow directors between the negative and positiveterminals 234, 235 and in engagement with the control component terminal208.

In this regard, FIG. 48 illustrates an enlarged view of the supply unit1102. As illustrated, the supply unit 1102 may be configured to supply aplurality of the flow directors 210. In some embodiments the supply unit1102 may include a vibratory arrangement. For example, the vibratoryarrangement may include a vibratory bowl 1110 and a supply track 1112.In some embodiments the vibratory bowl 1110 and/or the supply track 1112may be manufactured by Performance Feeders, Inc. of Oldsmar, Fla.

The flow directors 210 may be loaded directly into the vibratory bowl1110, or a vibratory hopper 1114 may supply the flow directors 210 tothe vibratory bowl in the manner described above. In this regard, acomponent level sensor 1116 may activate vibration of the vibratoryhopper 1114 based on the level of the flow directors 210 within thevibratory bowl 1110. The vibratory bowl 1110 may define a pathway 1118configured to arrange the flow directors 210 in a serially-alignedstream 1120 (see, FIG. 49). In this regard, the vibratory motion of thevibratory bowl 1110 may direct the flow directors 210 upwardly along thepathway 1118, which may narrow such that some flow directors falltherefrom and the flow directors that remain on the pathway becomeserially-aligned.

The vibratory bowl 1110 may be configured to arrange the flow directors210 generally vertically by the time the flow directors reach the supplytrack 1112. An actuator or gap (not shown) may be configured toindividually remove or realign the flow directors 210 in theserially-aligned stream 1120 when the flow directors are misaligned in adirection, as discussed above. The supply track 1112 may include a fullsensor 1132 configured to detect whether the supply track is full of theflow directors 210 and to thereby turn off the vibration of thevibratory bowl 1110, and a low level sensor 1134 configured to detectwhen the supply track is running low on the flow directors 210, toactive an indicator 1130 (see, FIG. 47) to inform an operator that theflow director coupling substation 510 is running low on the flowdirectors. In some embodiments the full sensor 1132 and the low levelsensor 1134 may comprise optical sensors that include an emitter and areceiver configured to detect whether a flow director 210 is positionedtherebetween.

Further, as illustrated in FIG. 49, the supply unit 1102 may include asingulator 1136 configured to singulate the flow directors 210 from theserially-aligned stream 1120. In this regard, the singulator 1136 mayinclude a stop 1138 (e.g., comprising a pin) that stops theserially-aligned stream 1120 of flow directors 210 from furtheradvancement. As illustrated, in one embodiment a vertical actuator 1140may be configured to move the stop 1138 vertically between a retractedposition and an extended position. The vertical actuator 1140 maydefault to the extended position such that the stop 1138 blocks theserially-aligned stream 1120 of flow directors 210 from moving. In thisregard, the stop 1138 may extend into a longitudinal hole 210′ (see,FIG. 1) defined through the flow directors 210. However, the verticalactuator 1140 may momentarily retract the stop 1138 to the retractedposition to allow one of the flow directors 210 to pass the stop. Thevertical actuator 1140 may return the stop 1138 to the extended positioninside of the subsequent flow director 210 after the outermost flowdirector passes thereunder.

After the outermost flow director 210 is released from the stop 1138,the flow director may contact a second stop 1144. At this time a secondvertical actuator 1146 may extend a guide pin 1148 into the longitudinalhole 210′ extending through the flow director 210. Thus, when ahorizontal actuator 1150 retracts the second stop 1144, the flowdirector 210 may fall down the guide pin 1148. In this regard, the guidepin 1148 may guide the flow director 210 to the feeder unit 1104, suchthat the flow director is singulated from the serially-aligned stream1120, and received by the feeder unit 1104.

As illustrated in FIG. 50, the feeder unit 1104 may comprise a rotarymember 1152 having a first engagement head 1154 a including a firstpocket 1156 a and a second engagement head 1154 b including a secondpocket 1156 b each configured to receive one of the flow directors 210from the supply unit 1102. The rotary member 1152 may comprise a firstarm 1158 a to which the first engagement head 1154 a is mounted and asecond arm 1158 b to which the second engagement head 1154 b is mounted.

FIGS. 49 and 50 illustrate the rotary member 1152 in a first receivingposition at which the first engagement head 1154 a is positionedproximate the singulator 1136. The rotary member 1152 may be configuredto swivel to a second receiving position at which the second engagementhead 1154 b is positioned proximate the singulator 1136. A singulationsensor 1160 (e.g., an optical sensor) may detect that the flow director210 has been singulated and delivered to one of the engagement heads1154 a, 1154 b. Accordingly, the rotary member 1152 may swivel betweenthe first receiving position (corresponding to a second deliveryposition) and a second receiving position (corresponding to a firstdelivery position) in the manner described above with respect to theother rotary members described herein.

Thus, the singulated flow directors 210 may be delivered to the firstassembly unit 1106 a and the second assembly unit 1106 b. FIG. 51illustrates the second assembly unit 1106 b. As illustrated, the secondassembly unit 1106 b may include a second robotic arm 1162 b and asecond end effector 1164 b. Similarly, the first assembly unit 1106 amay include a first robotic arm 1162 a (see, FIG. 47) and a first endeffector 1164 a (see, FIG. 52). Accordingly, the first end effector 1154b may be configured to engage a first flow director 210 a (see, FIG. 49)held in the first pocket 1156 a of the feeder unit 1104 and deliver thefirst flow director to the first base 204 a on a carriage 604 on thetrack 602 via movement of the first robotic arm 1162 a. As illustratedin FIG. 52, in some embodiments the first end effector 1154 a maycomprise first and second opposing portions 1166, 1168 configured toclamp the first flow director 210 a therebetween.

Accordingly, the track 602 may move the carriage 604 such that the firstbase 204 a is positioned for receipt of the first flow director 210 aand similarly, the second base 204 b is positioned for receipt of thesecond flow director 210 b. In this regard, as illustrated in FIG. 53,the track 602 may direct each carriage 604 through a first processingportion 1170 a and a second processing portion 1170 b at the flowdirector coupling substation 512. The first processing portion 1170 amay include a carriage sensor (not shown; see, e.g., carriage sensor1172 b), an initial locator sensor 1174 a, an initial stop 1176 a, alift stop 1178 a, a stop locator sensor 1180 a, and a lifter mechanism1182 a, which may function in the manner described above with respect tothe same components at the other substations.

Further, the first processing portion 1170 a may include a terminalspreader 1184. As illustrated, the terminal spreader 1184 may includefirst and second spreading pins 1186 a, 1186 b. In this regard, whilethe carriage 604 is stopped by the initial stop 1176 a, a verticalactuator 1188 of the terminal spreader 1184 may lower the firstspreading pin 1186 a between the first negative and positive heatingterminals 234 a, 235 a and lower the second spreading pin 1186 b betweenthe second negative and positive heating terminals 234 b, 235 b.Thereby, the negative and positive heating terminals 234, 235 may bespread apart from one another, such that insertion of the flow director210 therebetween and into engagement with the electronic controlcomponent 208 by the first robotic arm 1162 a is facilitated.

In this regard, the first and second opposing portions 1166, 1168 of thefirst end effector 1164 a (see, FIG. 52) may be configured to positionthe first flow director 210 a between the first negative and positiveheating terminals 234 a, 235 a. Further, each engagement head 1164 mayinclude opposing first and second terminal pinchers 1190, 1192, whichmay be configured to move inwardly and outwardly in directions that areperpendicular to the directions in which the first and second opposingportions 1166, 1168 move inwardly and outwardly. After the first flowdirector 210 a is positioned between the spread first negative andpositive heating terminals 234 a, 235 a by the first and second opposingportions 1166, 1168, the terminal pinchers 1190, 1192 may pinch thenegative and positive heating terminals against the side of the firstflow director 208 a, such that the flow director is securely positionedtherebetween.

While the carriage 604 is lifted by the lifter mechanism 1182 a, acomponent presence sensor 1194 a (e.g., comprising a light emitter and areceiver) may detect the presence of the flow director 210 a. Further, astorage transceiver 1196 a may write code to the storage module 624indicating whether or not the first flow director 210 a was properlycoupled to the first base 204 a based on the signal from the componentpresence sensor 1194 a, such that improperly assembled cartridges maynot be subjected to further assembly operations downstream. In this sameregard, the storage transceiver 1196 a may read the code on the storagemodule 624 to determine that the partially-assembled cartridge is fitfor further assembly prior to coupling the flow director 210 a to thebase 204 a.

Thereafter, the lifter mechanism 1182 a may lower the carriage 604 backonto the track 602. The carriage 604 may be directed downstream to thesecond processing portion 1170 b, at which the second assembly unit 1106b may perform substantially the same operations discussed above withrespect to the first assembly unit 1106 a on the second base 204 b, withthe exception of terminal spreading which is conducted upstream at theterminal spreader 1184. In this regard, as illustrated in FIG. 53, thesecond processing portion 1170 b may include a carriage sensor 1172 b,an initial locator sensor 1174 b an initial stop 1176 b, a lift stop1178 b, a stop locator sensor 1180 b, a lifter mechanism 1182 b, acomponent presence sensor 1194 b configured to detect whether the flowdirector 210 b is properly attached, and a storage transceiver 1196 b.

Note that the above-described operations may be conductedsimultaneously. In this regard, while the first engagement head 1154 adelivers the first flow director 210 a to the first robotic arm 1162 a,the second engagement head 1154 b may receive the second flow director210 b from the singulator 1136. Conversely, while the second engagementhead 1154 b delivers the second flow director 210 b to the secondrobotic arm 1162 b, the first engagement head 1154 a may receive thefirst flow director 210 a from the singulator 1136. Further, while thefirst robotic arm 1162 a couples the first flow director 210 a to thefirst base 204 a, the second robotic arm 1162 b may receive the secondflow director 210 b from the second engagement head 1154 b. Conversely,while the second robotic arm 1162 b couples the second flow director 210b to the second base 204 b, the first robotic arm 1162 a may receive thefirst flow director 210 a from the first engagement head 1154 a.Accordingly, rapid and efficient engagement of the flow directors 210 a,210 b with the bases 204 a, 204 b may be achieved.

The heating element coupling substation 514 may be positioned downstreamof the flow director coupling substation 512. FIG. 54 illustrates aperspective view of the heating element coupling substation 514. Theheating element coupling substation 514 may include a supply unit 1202.As illustrated, the supply unit 1202 may include a spool 1204 configuredto supply a substantially continuous heating element input 1206. In thisregard, the substantially continuous heating element input 1206 maycomprise a plurality of the heating elements 240 wound about anelongated liquid transport element 238, which may thereby be cut asdescribed below to define a plurality of liquid transport elements 238with a heating element 240 coupled thereto. Examples of heating elementswound about liquid transport elements are provided in U.S. Pat. App.Pub. Nos. 2014/0270730 to DePiano et al. and 2014/0157583 to Ward etal., which are incorporated herein by reference in their entireties.

The heating element coupling substation 514 may further include a casing1208. The casing 1208 may be substantially enclosed and opaque so as toprevent laser beams/and or other potentially harmful light from exitingtherefrom. In this regard, as discussed below, welding, and inparticular laser welding, in addition to the various other operationsdiscussed below, may be performed inside the casing 1208.

FIG. 55 illustrates a view of a portion of the supply unit 1202 insideof the casing 1208. As illustrated in FIG. 55, the supply unit 1202 mayfurther comprise a moveable clamp 1210 configured to pull thesubstantially continuous heating element input 1206 from the spool 1204into the casing 1206. The supply unit 1202 may additionally include aguide 1212 and a singulator 1214, which may comprise a cutter. In thisregard, the substantially continuous heating element input 1206 may bedirected through the guide 1212 (e.g., through an aperture definedtherethrough) and through the singulator 1214 to a feeder unit 1216.

As illustrated in FIG. 56, the feeder unit 1216 may include a firstengagement head 1218 a and a first gripper 1220 a coupled to a first arm1222 a of a rotary member 1224. The rotary member 1224 is illustrated ina first receiving position in FIG. 56, at which the first arm 1222 a ispositioned proximate the supply unit 1202. As illustrated in FIG. 57,the rotary member 1224 may further comprise a second arm 1222 bincluding a second engagement head 1218 b and a second gripper 1220 bcoupled thereto. The rotary member 1224 is illustrated in a seconddelivery position in FIG. 57, which corresponds to the first receivingposition illustrated in FIG. 56.

The supply unit 1202 may be configured to pull the substantiallycontinuous heating element input 1206 until a desired length thereof isreceived by the feeder unit 1216. In this regard, at least one imagingdevice may be configured to determine a length of the substantiallycontinuous heating element input 1206 pulled from the spool 1202. Asillustrated in FIG. 56, in one embodiment the supply unit 1202 mayinclude a first imaging device 1226 a and the feeder unit may include asecond imaging device 1226 b. The first imaging device 1226 a maydetermine a position of a heater area defined by the heating element 240(e.g., a portion of the heating element at which a plurality oftightly-wound coils are positioned), and the moveable clamp 1210 mayalign a center of the heater area with the second imaging device 1226 b.At this position, the substantially continuous heating element input1206 may extend through the first engagement head 1218 a to the firstgripper 1220 a, which may clamp onto the end of the substantiallycontinuous heating element input. The singulator 1214 may then cut thesubstantially continuous heating element input 1206 to singulate a firstheating element 240 and first liquid transport element 238 useable in asingle cartridge therefrom.

Accordingly, the rotary member 1224 may swivel from the first receivingposition at which a singulated heating element 240 and liquid transportelement 238 is received to a first delivery position, which correspondsto a second receiving position at which the second arm 1222 b of therotary member 1224 is positioned proximate the supply unit 1202. Asillustrated in FIG. 55, a stationary clamp 1228 may engage thesubstantially continuous heating element input 1206, such that themoveable clamp 1210 may release therefrom and move to an initialposition at which the moveable clamp may reengage the substantiallycontinuous heating element input. Thereby, the moveable clamp 1210 maypull the substantially continuous heating element input 1206 from thespool 1204 and direct the substantially continuous heating element inputthrough the second engagement head 1218 b such that the second gripper1220 b may engage an end thereof. Thereby, a second heating element 240and second liquid transport element 238 may be singulated from thesubstantially continuous heating element input 1206 by the singulator1214 in the manner described above.

As illustrated in FIG. 57, the heating element coupling substation 514may further comprise a first assembly unit 1230 a and a second assemblyunit 1230 b. The first assembly unit 1230 a may be configured toassemble the first heating element 240 and the first liquid transportelement 238 to the negative and positive heating terminals 234 a, 235 acoupled to the first base 204 a. Similarly, the second assembly unit1230 b may be configured to assemble the second heating element 240 andthe second liquid transport element 238 to the negative and positiveheating terminals 234 b, 235 b coupled to the second base 204 b. In thisregard, the first assembly unit 230 a may include a first robotic arm1232 a and the second assembly unit 230 b may include a second roboticarm 1232 b. The first robotic arm 1232 a may include a first endeffector 1234 a and the second robotic arm 1234 a may include a secondend effector 1234 b (see, FIG. 58).

As illustrated, in FIG. 58, each end effector 1234 a, 1234 b may includefirst and second opposing portions 1236, 1238. Each opposing portion1236, 1238 may include a first prong 1240 and a second prong 1242. Thefirst and second opposing portions 1236, 1238 of the end effectors 1234a, 1234 b may be configured to receive a singulated heating element 240and liquid transport element 238 therebetween.

In this regard, FIG. 59 illustrates an enlarged view of the firstengagement head 1218 a, which may be substantially similar to the secondengagement head 1218 b. As illustrated, the first engagement head 1218 amay include a plurality of depressible buttons 1244. The buttons 1244may be configured to recess into the first engagement head 1218 a whenengaged by the prongs 1240, 1242 of each of the opposing portions 1236,1238 of the end effector 1234 a. Note that although gaps could beprovided in the engagement heads 1218 a, 1218 b instead of thedepressible buttons 1244, the end of the substantially continuousheating element input 1206 may undesirably enter such gaps and bind whendirected into the engagement heads, rather than travel to the respectivegripper 1220 a, 1220 b as intended during singulation thereof.

Accordingly, the opposing portions 1236, 1238 of the first engagementhead 1218 a may depress the depressible buttons 1244 while extendingaround the singulated heating element 240 and liquid transport element238 received in the first engagement head. The first engagement head1218 a may then clamp onto the singulated heating element 240 and liquidtransport element 238. Thus, the first robotic arm 1234 a may lift thesingulated heating element 240 and liquid transport element 238 receivedin the first engagement head 1218 a and transport the singulated heatingelement and liquid transport element for assembly with the positiveheating terminal 235 and the negative heating terminal 234 a coupled toa first base 204 a.

In this regard, as illustrated in FIG. 60, the first assembly unit 1230a may further comprise a first processing portion 1244 a, and the secondassembly unit 1230 b may further comprise a second processing portion1244 b positioned along the track 602. Accordingly, the carriage 604 maybe directed along the track 602 to the first processing portion 1244 a.As illustrated, the first processing portion 1244 a may include acarriage sensor 1246 a, an initial locator sensor 1248 a, an initialstop 1250 a, a lift stop 1252 a (see, FIG. 61), a stop locator sensor(not shown; see, e.g., stop locator sensor 1254 b, and a liftermechanism 1256 a (see, FIG. 61), which may function in the mannerdescribed above with respect to the same components at the othersubstations.

Further, the first processing portion 1244 a may include a terminalfixation mechanism 1258 a and a laser 1260 a. FIG. 61 illustrates anenlarged view of the terminal fixation mechanism 1258 a. As illustrated,the terminal fixation mechanism 1258 a may include a clamp 1262 a. Theclamp 1262 a may include opposing terminal effectors 1264 a and opposingbase effectors 1266 a coupled thereto. Accordingly, when the carriage604 is lifted by the lifter mechanism 1256 a, the clamp 1262 a may acton the first base 204 a and the negative and positive heating terminals234 a, 235 a coupled thereto. In this regard, the base effectors 1266 amay clamp on opposing sides of the first base 204 a such that the firstbase is centered therebetween. Further, the terminal effectors 1264 amay clamp against opposing sides of the negative heating terminal 234 aand the positive heating terminal 235 a.

In this regard, FIG. 62 illustrates an enlarged partial view of theterminal effectors 1264 a. As illustrated, the terminal effectors 1264 amay include a protruding member 1268 and a recessed member 1270. Theprotruding member 1268 and the recessed member 1270 may be configured toclamp the negative and positive heating terminals 234 a, 235 atherebetween. In particular, the protruding member 1268 may define afirst shoulder 1272 a configured to engage the negative heating terminal234 a and a second should 1272 b configured to engage the positiveheating terminal 235 a. Similarly, the recessed member 1270 may define afirst shoulder 1274 a configured to engage the negative heating terminal234 a and a second shoulder 1274 b configured to engage the positiveheating terminal 235 a. Accordingly, the negative heating terminal 234 amay be clamped between the first shoulder 1272 a of the protrudingmember 1268 and the first shoulder 1274 a of the recessed member 1270.Similarly, the positive heating terminal 235 a may be clamped betweenthe second shoulder 1272 b of the protruding member 1268 and the secondshoulder 1274 b of the recessed member 1270.

During this clamping operation, a center portion 1272 c of theprotruding member 1268 may extend between the negative and positiveheating terminals 234 a, 235 a. Further, outer prongs 1274 c defined bythe recessed member 1270 may extend around the outside of the negativeand positive heating terminals 234 a, 235 a. Accordingly, the centerportion 1272 c of the protruding member 1268 and the outer prongs 1274 cof the recessed member 1270 may position the negative and positiveheating terminals 234 a, 235 a at a fixed spacing corresponding to adesired spacing of the negative and positive heating terminals forattachment of the heating element 240 thereto.

In this regard, the robotic arm 1232 a may position the end effector1234 a such that the heating element 240 and the liquid transportelement 238 are in proximity to the negative and positive heatingterminals 234 a, 235 a. In particular, a center of a heating portion ofthe heating element 240 may be aligned with a center of the negative andpositive heating terminals 234 a, 235 a via movement of the robotic arm1232 a. In this regard, as illustrated in FIG. 60, the first processingportion 1244 a may further comprise an imaging device 1270 a configuredto capture images of the negative and positive heating terminals 234 a,235 a, and the heating element 240, such that the robotic arm 1232 a mayalign the center of the heating element 240 with the center of thenegative and positive heating terminals 234 a, 235 a based on the imagesthereof. Additional details with respect to the alignment of thenegative and positive heating terminals with the heating element aredescribed in U.S. patent application Ser. No. 14/227,159, filed Mar. 27,2014, to Ampolini et al., which is incorporated herein by reference inits entirety.

Once aligned, the laser 1260 a may weld the heating element 240 to oneof the negative heating element 234 a and the positive heating element235 a. Then the laser 1260 a may weld the heating element 240 to theother of the negative heating element 234 a and the positive heatingelement 235 a. For example, the laser 1260 a may weld the heatingelement 240 to the negative heating element 234 a and then move to asecond position to weld the positive heating element 235 a. In thisregard, the laser 1260 a and the imaging device 1270 a may be mounted toa slide 1272 a configured to move the laser and the camera between firstand second welding positions. Accordingly, the heating element 240 maybe welded to the negative and positive heating terminals 234 a, 235 a,which may thereby indirectly couple the liquid transport element 238 tothe negative and positive heating terminals as a result of the heatingelement being coiled around, or otherwise attached to the liquidtransport element.

As illustrated in FIG. 57, a vent 1275 may be provided inside the casing1208. The vent 1275 may be employed to remove smoke and gases associatedwith laser welding from the casing 1208. Additional details with respectto the welding operation are provided in U.S. patent application Ser.No. 14/227,159, filed Mar. 27, 2014, to Ampolini et al., which isincorporated herein by reference in its entirety, as noted above.Further, although use of laser welding is described herein, it should beunderstood that the heating element may be attached to the negative andpositive heating terminals in a variety of manners. For example, arcwelding, metal inert gas welding (MIG), tungsten inert gas welding(TIG), plasma welding, etc. may be employed in other embodiments. Morebroadly, the heating element may be attached to the heating terminalsvia other methods outside of welding, such as via soldering and viamechanical connectors. Accordingly, it should be understood that variousother embodiments of coupling methods and related equipment outside oflaser welding may be employed without departing from the scope of thepresent disclosure.

A component presence sensor 1278 a (e.g., comprising a light emitter andreceiver) may detect whether or not the heating element 240 was properlycoupled to the negative and positive heating terminals 234 a, 235 a. Forexample, the component presence sensor 1278 a may detect whether or notthe heating element 240 and/or the liquid transport element are presentwhile the carriage 604 is lifted by the lifter mechanism 1256 a (see,FIG. 61). Thereby, this information may be written to the storage module624 by a storage transceiver 1276 a, such that in the event the heatingelement 240 is not detected, further operations may not be performed onthe partially-assembled cartridge. In this same regard, the storagetransceiver 1276 a may read the code on the storage module 624 todetermine that the partially-assembled cartridge is fit for furtherassembly prior to coupling the heating element 240 to the negative andpositive heating terminals 234, 235.

After welding at the first processing portion 1244 a, the liftermechanism 1256 a (see, FIG. 61) may lower the carriage 604 back intoengagement with the track 602. The carriage 604 may be directed to thesecond processing portion 1244 b, which may include substantially thesame equipment as the first processing portion. In this regard, asillustrated in FIG. 60, the second processing portion 1244 b may includea carriage sensor 1246 b, an initial locator sensor 1248 b, an initialstop 1250 b, a lift stop 1252 b, a stop locator sensor 1254 b, and alifter mechanism 1256 b, a terminal fixation mechanism 1258 b, a laser1260 b, a storage transceiver (not shown; see storage transceiver 1276a), and a component presence sensor 1278 b. Accordingly, the secondprocessing portion 1244 b may couple a second heating element 240 and asecond liquid transport element 238 to the second negative and positiveheating terminals 234 b, 235 b. Note that the above-described operationsmay be conducted simultaneously. In this regard, while the firstengagement head 1218 a delivers the first heating element 240 and thefirst liquid transport element 238 to the first robotic arm 1232 a, thesecond engagement head 1218 b may receive the second heating element andthe second liquid transport element from the supply unit 1202.Conversely, while the second engagement head 1218 b delivers the secondheating element 240 and the second liquid transport element 238 to thesecond robotic arm 1232 b, the first engagement head 1220 a may receivethe first heating element and the first liquid transport element fromthe supply unit 1202. Further, while the first robotic arm 1232 acouples the first heating element 240 and the first liquid transportelement 238 to the negative and positive heating terminals 234 a, 234 b,the second robotic arm 1232 b may receive the second heating element andthe second liquid transport element from the second engagement head 1218b. Conversely, while the second robotic arm 1232 b couples the secondheating element 240 and liquid transport element 238 to the negative andpositive heating terminals 234 b, 235 b, the first robotic arm 1232 amay receive the first heating element and the first liquid transportelement from the first engagement head 1220 a. Accordingly, rapid andefficient engagement of the heating elements and liquid transportelements with the negative and positive heating terminals may beachieved.

The reservoir and outer body coupling substation 516 may be positioneddownstream of the heating element coupling substation 514. FIG. 63illustrates a perspective view of the reservoir and outer body couplingsubstation 516. As illustrated, the reservoir and outer body couplingsubstation 516 may include a supply unit 1302. The supply unit 1302 mayinclude a reservoir supply unit 1304 and an outer body supply unit 1306.

As illustrated, the reservoir supply unit 1304 may include a first spool1308 a and a second spool 1308 b each configured to respectively supplya substantially continuous reservoir substrate input 1310. Each spool1308 a, 1308 b may supply the substantially continuous reservoirsubstrate input 1310 to a respective moveable clamp 1312, one of whichis illustrated in FIG. 64. Each moveable clamp 1312 may be configured topull the substantially continuous reservoir substrate input 1310 from arespective spool 1308 a, 1308 b. Thereby, the substantially continuousreservoir substrate input 1310 may be directed to a singulator 1314. Asillustrated in FIG. 65, the singulator 1314 may include a reservoirgripper 1316 which may include four prongs 1318. When the end of thesubstantially continuous reservoir substrate input 1310 is directed downinto the reservoir gripper 1316, the prongs 1318 may clamp againstopposing sides thereof.

At this time a stationary clamp 1320, as illustrated in FIG. 64, mayclamp against the substantially continuous reservoir substrate input1310 and the moveable clamp 1312 may return to a starting position(e.g., by moving upwardly), at which the moveable clamp grips thesubstantially continuous reservoir substrate input again. A cutter 1322of the singulator 1314 may then cut the substantially continuousreservoir substrate input 1310 such that the reservoir gripper 1316holds a singulated reservoir substrate 214 (see, e.g., FIG. 1).

A vacuum gripper 1324 (see, FIG. 65) may then extend into contact withthe reservoir substrate 214 held by the reservoir gripper 1316. In thisregard, the vacuum gripper 1324 may apply negative pressure to thereservoir substrate 214 such that the reservoir substrate wraps around acurved outer nose 1326 defined by the vacuum gripper. The reservoirgripper 1316 may then release the reservoir substrate 214 and retractdownwardly. Thereby, the reservoir substrate 214 is positioned forreceipt by a feeder unit 1328, as discussed below.

While the singulated reservoir substrates 214 are supplied by thereservoir supply unit 1304 in the manner described above, the outer bodysupply unit 1306 may supply the outer bodies 216 (see, e.g., FIG. 1). Inthis regard, as illustrated in FIG. 66, the outer body supply unit 1306may include a vibratory arrangement. For example, the vibratoryarrangement may include a vibratory bowl 1330 and a supply track 1332.In some embodiments the vibratory bowl 1330 and/or the supply track 1332may be manufactured by Performance Feeders, Inc. of Oldsmar, Fla. Theouter bodies 216 may be loaded directly into the vibratory bowl 1330, ora vibratory hopper 1334 may supply the outer bodies 216 to the vibratorybowl in the manner described above with respect to other vibratory bowlsand vibratory hoppers described herein. In this regard, a componentlevel sensor 1336 may activate vibration of the vibratory hopper 1334based on the level of the outer bodies 216 within the vibratory bowl1330.

The vibratory bowl 1330 may define a pathway 1338 configured to arrangethe outer bodies 216 in a serially-aligned stream 1340. In this regard,the vibratory motion of the vibratory bowl 1330 may direct the outerbodies 216 upwardly along the pathway 1338, which may narrow such thatsome outer bodies fall therefrom and the outer bodies that remain on thepathway become serially-aligned. The vibratory bowl 1330 may beconfigured to arrange the outer bodies 216 generally vertically by thetime the outer bodies reach the supply track 1332. An actuator or gap(not shown) may be configured to individually remove or realign theouter bodies in the serially-aligned stream 1340 when the outer bodiesare misaligned in a direction, as discussed above with respect to othercomponents. The supply track 1332 may include a full sensor 1342configured to detect whether the supply track is full of the outerbodies 216 and to thereby turn off the vibration of the vibratory bowl1330, and a low level sensor (not shown; see, e.g., the full sensor1342) configured to detect when the supply track 1332 is running low onthe outer bodies 216, to active an indicator 1346 (see, FIG. 63) toinform an operator that the reservoir and outer body coupling substation516 is running low on the outer bodies 216. In some embodiments the fullsensor 1342 and the low level sensor may comprise optical sensors thatinclude an emitter and a receiver configured to detect each outer body216 passing thereby. Note that the indicator 1346 may alternatively oradditionally be activated when one or both of the spools 1308 a, 1308 bruns low on the substantially continuous reservoir substrate input 1310.

Further, as illustrated in FIG. 67, the outer body supply unit 1306 mayinclude a singulator 1348 configured to singulate the outer bodies 216from the serially-aligned stream 1340. In this regard, the singulator1348 may include a stop 1350. As illustrated, in one embodiment the stop1350 may comprise an end wall 1352 configured to stop theserially-aligned stream 1340 of outer bodies 216 from furtheradvancement. As illustrated, a horizontal slot 1354 may be definedthrough the end wall 1352. A singulation sensor 1356 may detect that anoutermost one of the outer bodies 216 is positioned for singulation. Inthis regard, the stop 1350 may include an upper cutout 1358 that mayallow for access to the outer body 216 at the end of theserially-aligned stream 1340.

Accordingly, the feeder unit 1328 may receive one of the outer bodies216. In this regard, as illustrated in FIG. 68, the feeder unit 1328 mayinclude an initial outer body feeder 1360. The initial outer body feeder1360 may include a first engagement head 1362 a and a second engagementhead 1362 b coupled to opposing ends of a beam 1364. As illustrated inFIGS. 67 and 68, each of the engagement heads 1362 a, 1362 b may includefirst and second opposing portions 1366, 1368 configured to clamp anouter body 216 therebetween.

The beam 1364 may be configured to raise, lower, and shift laterallybetween a first receiving position, which corresponds to a seconddelivery position, and a second receiving position, which corresponds toa first delivery position. In this regard, the beam 1364 may lower suchthat the opposing portions 1366, 1368 of the first engagement head 1362a extend into the upper cutout 1358 in the stop 1350 and clamp onto anoutermost outer body 216 in the serially-aligned stream 1340. While thefirst engagement head 1362 a engages a first outer body 216, a secondouter body may be delivered to a second outer body and reservoirsubstrate feeder 1370 b, which is illustrated in FIG. 71. After thefirst engagement head 1362 a engages the first outer body 216, the beammay lift upwardly, shift position laterally, and lower to deliver thefirst outer body to a first outer body and reservoir substrate feeder1370 a, which is also illustrated in FIG. 69. At this time, the secondengagement head 1362 b is positioned proximate the singulator 1348 andengages a second outer body 216.

Accordingly, the initial outer body feeder 1360 may alternatingly feedouter bodies 216 to the first outer body and reservoir substrate feeder1370 a and the second outer body and reservoir substrate feeder 1370 b.While the first outer body and reservoir substrate feeder 1370 areceives a first outer body 216 from the initial outer body feeder 1360,the first outer body and reservoir substrate feeder also receives areservoir substrate 214 singulated from the substantially continuousreservoir input 1310 supplied by the first spool 1308 a in the mannerdescribed above. Conversely, while the second outer body and reservoirsubstrate feeder 1370 b receives a second outer body 216 from theinitial outer body feeder 1360, the second outer body and reservoirsubstrate feeder also receives a reservoir substrate 214 singulated fromthe substantially continuous reservoir input 1310 supplied by the secondspool 1308 b in the manner described above.

In this regard, as illustrated in FIG. 71, the first and second outerbody and reservoir substrate feeders 1370 a, 1370 b may each include arotary member 1372, first and second substrate grippers 1374′, 1374″positioned at opposing ends of the rotary member, and first and secondouter body supporters 1376′, 1376″ positioned at opposing ends of therotary member. As illustrated, the outer body supporters 1376′, 1376″may comprise upwardly extending pins. Thus, the engagement heads 1362 a,1362 b of the initial body feeder 1360 (see, e.g., FIG. 68) may positionand release the outer bodies 216 such that the outer body extenders1376′, 1376″ extend at least partially through the outer bodies suchthat the outer bodies may be held in place.

Further, as illustrated in FIG. 70, the substrate grippers 1374′, 1374″may each include first and second opposing portions 1378′, 1378″configured to receive the reservoir substrate 214 therebetween. In thisregard, a distal end of each opposing portion 1378′, 1378″ may define alip configured to engage a respective longitudinal end of the reservoirsubstrate 214. Accordingly, the reservoir substrate 214 may retain asubstantially U-shaped configuration when removed from a curved outernose 1326 of the vacuum gripper 1324 (see, e.g., FIG. 65). Note that inorder to facilitate transfer of the reservoir substrate 214 from thevacuum gripper 1324 to one of the substrate grippers 1374′, 1374″, insome embodiments the vacuum gripper may momentarily apply a positivepressure to the reservoir substrate when one of the substrate grippersis positioned to receive the reservoir substrate therefrom. Further, insome embodiments the substrate grippers 1374′, 1374″ may apply anegative pressure to the reservoir substrate 214 in order to furtherimprove grasping thereof.

Once the first outer body and reservoir substrate feeder 1370 a or thesecond outer body and reservoir substrate feeder 1370 b receives theouter body 216 and the reservoir substrate 214, the rotary member 1372may rotate such that the reservoir substrate and the outer body arepositioned for receipt by a respective one of a first assembly unit 1380a and a second assembly unit 1380 b, as illustrated in FIG. 69. In thisregard, the first outer body and reservoir substrate feeder 1370 asupplies the outer bodies 216 and reservoir substrates 214 to the firstassembly unit 1380 a and the second outer body and reservoir substratefeeder 1370 b (see, FIG. 71) supplies the outer bodies and the reservoirsubstrates to the second assembly unit 1380 b.

In the illustrated embodiment the second assembly unit 1380 b ispositioned upstream of the first assembly unit 1380 a. Accordingly, areservoir substrate 214 and an outer body 216 may be assembled to thesecond partially-assembled cartridge including the second base 204 b inadvance of assembling a reservoir substrate and an outer body to thefirst partially-assembled cartridge including the first base 204 a.However, as may be understood, this order may be reversed in otherembodiments.

Accordingly, the carriage 604 may be directed along the track 602 forreceipt of the reservoir substrate 214 and the outer body 216. In thisregard, as illustrated in FIG. 71, the track 602 may direct eachcarriage 604 through a first processing portion 1382 a of the firstassembly unit 1380 a and a second processing portion 1382 b of thesecond assembly unit 1380 b at the reservoir and outer body couplingsubstation 516. The first processing portion 1382 a may include acarriage sensor 1384 a, an initial locator sensor 1386 a, an initialstop 1388 a, a lift stop 1390 a (see, FIG. 70), a stop locator sensor1392 a, and a lifter mechanism 1394 a, which may function in the mannerdescribed above with respect to the same components at the othersubstations. Similarly, the second processing portion 1382 b may includea carriage sensor (not shown; see, e.g., carriage sensor 1384 a), aninitial locator sensor 1386 b, an initial stop 1388 b, a lift stop 1390b (not shown; see, e.g. lift stop 1390 a in FIG. 70), a stop locatorsensor 1392 b, and a lifter mechanism 1394 b. Accordingly, the carriage604 may be directed along the track 602 to the second processing portion1382 b at which the second assembly unit 1380 b assembles the reservoirsubstrate 214 and the outer body 216 to the second base 204 b followedby the first processing portion 1382 a at which the first assembly unit1380 a assembles the reservoir substrate and the outer body to the firstbase 204 a.

In this regard, as illustrated in FIG. 69, the first assembly unit 1380a may include a robotic arm 1396. The second assembly unit 1380 b mayalso include a robotic arm 1396, which may be substantially similar tothe robotic arm of the first assembly unit 1380 a. The robotic arm 1396may be configured to insert a partially-assembled cartridge into theouter body 216 (e.g., by directing the outer body over thepartially-assembly cartridge in the manner discussed below). In thisregard, the carriage 604 may transport one or more (e.g., two asdescribed above) partially-assembled cartridges along the track 602 tothe reservoir and outer body coupling substation 516, and as describedabove, such partially-assembled cartridges may include a base 204, anegative heating terminal 234, a positive heating terminal 235, aheating element 240, a liquid transport element 238, a control componentterminal 206, and an electronic control component 208. As furtherdescribed above, the negative heating terminal 234 and the positiveheating terminal 235 may be directly coupled to the base 204, and theheating element 240 may be directly coupled to the negative heatingterminal and the positive heating terminal. The heating element 240 maybe coiled about the liquid transport element 238 such that the liquidtransport element is indirectly coupled to the negative heating terminal234, the positive heating terminal 235, and the base 204. Further, thecontrol component terminal 206 may be directly coupled to the base 204and may engage the electronic control component 208.

As illustrated in FIG. 70, each robotic arm 1396 may include a bendingmechanism 1398. The bending mechanism 1398 may be configured to receivethe partially-assembled cartridge therein so as to bend the liquidtransport element 238 against the negative heating terminal 234 and thepositive heating terminal 235. In this regard, as illustrated in FIG.72, the bending mechanism 1398 may comprise a hollow tube that extendsover the partially-assembled cartridge so as to press the ends of theliquid transport element 238, and the heating element 240 in theillustrated embodiment, down into contact with the negative heatingterminal 234 and the positive heating terminal 235.

While the liquid transport element 238 and the heating element 240 arebent against the negative heating terminal 234 and the positive heatingterminal 235, the substrate gripper 1374′ may wrap the reservoirsubstrate 214 at least partially around the bending mechanism 1398. Inthis regard, as illustrated in FIG. 70, the opposing portions 1378′,1378″ may clamp towards one another and around the bending mechanism1398. The bending mechanism 1398 may then retract relative to thepartially-assembled cartridge (e.g., by moving upward in terms of theillustrated orientation) following wrapping of the reservoir substrate214 such that the reservoir substrate is wrapped at least partiallyabout the negative heating terminal 234 and the positive heatingterminal 235 and in contact with the liquid transport element 238.

As illustrated in FIG. 70, each robotic arm 1396 may further comprise anouter body gripper 1400. The outer body gripper 1400 may include firstand second opposing portions 1402′, 1402″. The opposing portions 1402′,1402″ of the outer body gripper may be configured to move between aseparated configuration, which is illustrated and in which the opposingportions are separated from one another, and a contracted configuration,in which the opposing portions contact one another.

While the robotic arm 1396 lowers the bending mechanism 1398 over thepartially-assembled cartridge, the outer body gripper 1400 may also belowered such that the first and second opposing portions 1402′, 1402″extend around an outer body 216 supported by the one of the outer bodysupporters 1376′, 1376″ positioned proximate the track 602. Accordingly,the outer body gripper 1440 may be configured to receive the outer body216 therein while the bending mechanism 1398 receives thepartially-assembled cartridge therein. Once lowered, the first andsecond opposing portions 1402′, 1402″ may move toward one another suchthat the outer body gripper 1400 retains the outer body 216 therein.Thus, when the robotic arm 1396 lifts the bending mechanism 1398 afterthe reservoir substrate 214 is wrapped thereabout, the outer bodygripper 1400 may lift the outer body 216 from the one of the outer bodysupporters 1376′, 1376″ to which the outer body was engaged.

Further, the robotic arm 1396 may direct the outer body gripper 1400with the outer body 216 positioned therein over the partially-assembledcartridge. In this regard, the robotic arm 1396 may rotate (e.g., about90 degrees) such that the bending mechanism 1398 is positioned away fromthe carriage 604, and thereby does not come into contact with thecarriage, while the outer body gripper 1400 extends downwardly towardthe partially-assembled cartridge. As the outer body 216 is directedover the partially-assembled cartridge, at least a portion of thenegative heating terminal 234, the positive heating terminal 235, theheating element 240, and the liquid transport element 238, and theelectronic control component 208 and the control component terminal 206in embodiments including these components) are received in the outerbody.

In order to facilitate insertion of the partially-assembled cartridgeinto the outer body 216, the outer body gripper 1400 may apply anegative pressure longitudinally through the outer body via the outerbody gripper 1400. In this regard, as illustrated in FIG. 70, the outerbody gripper 1400 may further comprise a piston 1404. The piston 1404may be configured to engage an end of the outer body 216 when the firstand second opposing portions 1402′, 1402″ of the outer body gripper 1400are in the contracted configuration with the outer body therein andapply the negative pressure through the outer body. In this regard, forexample, the piston 1404 may be hollow and coupled to a suction system1405 configured to supply the negative pressure. Application of thenegative pressure to the partially-assembled cartridge through the outerbody 216 may assist in inserting the partially-assembled cartridge intothe outer body by pulling the reservoir substrate 214 into the outerbody during insertion. Thereby, issues with respect to the reservoirsubstrate 214 shifting from the desired position or not becoming fullyinserted into the outer body 216 may be avoided.

As the outer body 216 is pressed downwardly over the partially-assembledcartridge, the opposing portions 1378′, 1378″ of the substrate gripper1374′ may release the reservoir substrate 214, and cease applyingnegative pressure thereto in embodiments in which the substrate gripperapplies negative pressure to the reservoir substrate. The rotary member1372 of the outer body and reservoir substrate feeder 1370 b may thenswivel (e.g., by rotating about one hundred and eighty degrees) totransport an additional outer body 216 into proximity to the robotic arm1396 for attachment to a partially-assembled cartridge on the nextcarriage 604.

The piston 1404 may be further configured to press the outer body 216into engagement with the base 204 b. In this regard, the piston 1404 maypress against an upper end of the outer body 216 (e.g., by sitting flushagainst the upper end of the outer body). In this regard, the piston1404 may define one or dimensions (e.g., a diameter) that aresubstantially equal to that of the outer body 216. Thereby, the outerbody 216 may be pressed over the partially-assembled cartridge into fullengagement with the base 204 b.

A component presence sensor 1406 b (e.g., comprising a light emitter andreceiver) may detect whether or not the outer body 216 was properlycoupled to the base 204 b. For example, the component presence sensor1406 b may detect whether or not the outer body 216 is present while thecarriage 604 is lifted by the lifter mechanism 1394 b. Thereby, thisinformation may be written to the storage module 624 by a storagetransceiver (not shown; see, e.g., storage transceiver 1408 a) at thesecond processing portion 1382 b. Thus additional operations may not beperformed on the partially-assembled cartridge if the outer body 216 isnot properly assembled therewith, so as to avoid damage to the assemblyequipment and waste of additional components. In this same regard, thestorage transceiver may read the code on the storage module 624 todetermine that the partially-assembled cartridge is fit for furtherassembly prior to coupling the outer body 216 to the base 204.

Once the outer body 216 is pressed onto the partially-assembledcartridge, the lifter mechanism 1394 b may lower the carriage back ontothe track 602. The carriage 604 may then be directed to the firstprocessing portion 1382 a, at which substantially the same operationsmay occur to couple a first outer body 216 to the first base 204 a.Thereafter, as described above with respect to the second processingportion 1382 b, a component presence sensor 1406 a (e.g., comprising alight emitter and receiver) may detect whether or not the outer body 216was properly coupled to the base 204 a. Thereby, this information may bewritten to the storage module 624 by a storage transceiver 1408 a at thefirst processing portion 1382 a. Thus additional operations may not beperformed on the partially-assembled cartridge if the outer body 216 isnot properly assembled therewith, so as to avoid damage to the assemblyequipment and waste of additional components. In this same regard, thestorage transceiver 1408 a may read the code on the storage module 624to determine that the partially-assembled cartridge is fit for furtherassembly prior to coupling the outer body 216 to the base 204.

Note that the above-described operations may be conductedsimultaneously. In this regard, for each of the outer body and reservoirsubstrate feeders 1370 a, 1370 b, while one of the substrate grippers1374′, 1374″ receives a reservoir substrate 1314, the other of thesubstrate grippers may wrap the reservoir substrate around the bendingmechanism 1398. Further, while one of the substrate grippers 1374′,1374″ receives a reservoir substrate 1314, an associated one of theouter body supporters 1376′, 1376″ may receive an outer body. Variousother operations conducted by the reservoir and outer body couplingsubstation 516 may be conducted simultaneously so as to reduce cycletimes. Accordingly, rapid and efficient engagement of the reservoirsubstrate and outer body with the partially-assembled cartridges may beachieved. The outer body crimping and inspection substation 518 may bepositioned downstream of the reservoir and outer body couplingsubstation 516. FIG. 73 illustrates a partial side view of the outerbody crimping and inspection substation 518. As illustrated, the outerbody crimping and inspection substation 518 may include a first crimperunit 1502 a, a second crimper unit 1502 b, a first transfer unit 1504,an inspection and processing unit 1506, and a second transfer unit 1508.

FIG. 74 illustrates a perspective view of the first crimper unit 1502 aand the second crimper unit 1502 b. As illustrated, the first and secondcrimper units 1502 a, 1502 b may each include a crimper 1510. Thecrimper 1510 may comprise multiple sections configured to extend aroundthe outer body 216 and crimp the outer body to the base 204. Thereby,the first crimper unit 1502 a may crimp an outer body 216 to the firstbase 204 a, whereas the second crimper unit 1502 b may crimp a secondouter body 216 to the second base 204 b. Various details with respect tothe configuration of example embodiments of crimpers that may beemployed in the first and second crimper units 1502 a, 1502 b areprovided in U.S. patent application Ser. No. 14/227,159 to Ampolini etal., filed Mar. 27, 2014, which is incorporated herein by reference inits entirety. As further illustrated in FIG. 74, the first crimper unit1502 a and the second crimper unit 1502 b may each include a processingportion 1512 configured to prepare each partially-assembled cartridge onthe carriage 604 for crimping as the carriage is directed along thetrack 602. In this regard, the processing portions 1512 may respectivelyposition the carriage 604 for crimping a first outer body 216 at thefirst crimper unit 1502 a and position the carriage for crimping asecond outer body at the second crimper unit 1502 b.

In this regard, FIG. 75 illustrates a perspective view of the processingportion 1512 respectively included at each of the first crimper unit1502 a and the second crimper unit 1502 b. As illustrated, theprocessing portion 1512 may include a carriage sensor 1514, an initiallocator sensor 1516, an initial stop 1518, a stop locator sensor 1520, alift stop 1522, and a lifter mechanism 1524, which may function in themanner described above with respect to the same components at the othersubstations.

Thus, the carriage 604 may be lifted at each of the first crimper unit1502 a and the second crimper unit 1502 b by the respective liftermechanism 1524. While lifted at the first crimper unit 1502 a the firstouter body 216 may be crimped onto the first base 204 a. Similarly,while lifted at the second crimper unit 1502 b the second outer body 216may be crimped onto the second base 204 b.

After each crimping operation a component presence sensor 1526 (e.g.,comprising a light emitter and receiver) may detect whether thepartially-assembled cartridge that was crimped is still present.Thereby, a storage transceiver 1528 may write code to the storage module624 indicating whether or not the partially-assembled cartridgesubjected to the crimping operation is present, so that additionaloperations may not be performed thereon when the cartridge is notdetected. In this same regard, the storage transceiver 1528 may read thecode on the storage module 624 to determine that the partially-assembledcartridge is fit for further assembly prior to crimping the outer body216 to the base 204. Thereafter, the lifter mechanism 1524 may lower thecarriage 604 into engagement with the track 602 such that the carriageis directed downstream. In this regard, each carriage 604 may bedirected from the first crimper unit 1502 a to the second crimper unit1502 b to the first transfer unit 1504.

FIG. 76 illustrates an enlarged partial view of the first transfer unit1504. As illustrated, the first transfer unit 1504 may include aprocessing portion 1530. The processing portion 1530 may position thecarriage 604 for transfer of the partially-assembled cartridges to theinspection and processing unit 1506. In this regard, the processingportion 1530 may include a carriage sensor (not shown; see, e.g.,carriage sensor 1514 in FIG. 75), an initial locator sensor (not shown;see, e.g., initial locator sensor 1516 in FIG. 75), an initial stop1532, a stop locator sensor 1534, a lift stop 1536, and a liftermechanism 1538, which may function in the manner described above withrespect to the same components at the other substations. Accordingly,the carriage 604 may be lifted by the lifter mechanism 1538. Thereby,the first transfer unit 1504 may transfer the first and secondpartially-assembled cartridges to the inspection and processing unit1506.

In this regard, as further illustrated in FIG. 76, the first transferunit 1504 may include an end effector 1540. The end effector 1540 mayinclude first and second opposing portions 1542, 1544 configured tograsp a partially-assembled cartridge. For example, the first and secondopposing portions 1542, 1544 of the end effector 1540 may be configuredto clamp against opposing sides of the base 204 and/or the outer body204. Thereby, a robotic arm 1546 of the first transfer unit 1504 mayindividually lift and remove first and second partially-assembledcartridges from the carriage 604 and transfer the partially-assembledcartridges to the inspection and processing unit 1506.

The processing portion 1530 of the first transfer unit 1504 may furthercomprise a first component presence sensor 1548 a and a second componentpresence sensor 1548 b (e.g., respectively comprising a light emitterand receiver). The first component presence sensor 1548 a may beconfigured to detect whether the first partially-assembled cartridge issuccessfully removed from the carriage by the robotic arm 1546 and theend effector 1540. Similarly the second component presence sensor may beconfigured to determine whether the second partially-assembled cartridgeis removed by the robotic arm 1546 and the end effector 1540. Thereby, astorage transceiver 1542 may write code to the storage module 624indicating whether or not the partially-assembled cartridges aresuccessfully removed from the carriage 604. In this regard, when thepartially-assembled cartridges are successfully removed from thecarriage 604, the track 602 may direct the carriage back to the stagingarea 602 a, such that the carriage may be reused with each of thesubstations 502-518 (see, FIG. 4) in the manner described above.However, in instances in which one or both of the partially-assembledcartridges is unsuccessfully removed from the carriage 604, the carriagemay be directed off of the track 602, or an operator may be alerted,such that the carriage is not reused with the partially-assembledcartridge still attached.

The first transfer unit 1504 may transfer the partially-assembledcartridges to the inspection and processing unit 1506. As illustrated inFIG. 77, in one embodiment the inspection and processing unit 1506 mayinclude an audit chute 1547. In this regard, partially-assembledcartridges may be selected at various stages of assembly for review forquality control or other purposes. When a partially-assembled cartridgeis selected for review, after reaching a desired state of completion,the storage module 624 may be programmed to indicate that suchpartially-assembled cartridge should not be subjected to any furtherassembly, in the same manner discussed above with respect to cartridgesthat are determined to be defective. In this regard, the various storagetransceivers described above may read the storage module 624 and thecode thereon may instruct the respective substations to not performfurther assembly operations on the partially-assembled cartridge.Thereby, the partially-assembled cartridges may reach the first transferunit 1504 under any of a variety of states of completion, such that thepartially-assembled cartridges may be directed to the audit chute 1547and inspected to ensure that each of the substations 502-518 of thecartridge assembly system 402 are operating properly.

The first transfer unit 1504 may transfer the remainder of thepartially-assembled cartridges, which are not directed to the auditchute 1547 to an indexing table 1550 of the inspection and processingunit 1506. As illustrated, the indexing table 1550 may include aplurality of first grippers 1552 a and second grippers 1552 b extendingradially therefrom. The first grippers 1552 a may be configured toreceive the first partially-assembled cartridges and the second grippers1552 b may be configured to receive the second partially-assembledcartridges. Thereby, as the indexing table 1550 indexes (e.g., by movingcounterclockwise in terms of the illustrated orientation), thepartially-assembled cartridges may be transported between a plurality ofangular stops.

In this regard, the first transfer unit 1504 may transport thepartially-assembled cartridges to a first angular stop 1554. Asillustrated in FIG. 78, the first angular stop 1554 may comprise a firstreject chute 1556. Thus, when the first transfer unit 1504 positionseach partially-assembled cartridge at the first angular stop 1554, theassociated gripper 1552 a, 1552 b to which the partially-assembledcartridge is delivered may function in one of two manners. If thepartially-assembled cartridge is defective in one or more respects, asrecorded on the storage module 624, and as read by the storagetransceiver 1542 (see, FIG. 76), the gripper 1552 a, 1552 b to which thepartially-assembled cartridge is delivered may not clamp thereon.Accordingly, when the end effector 1540 releases a defectivepartially-assembled cartridge, such cartridge may fall into the firstreject chute 1556 for disposal, further analysis, or recycling of thecomponents thereof.

Conversely, when a partially-assembled cartridge is not determined to bedefective, the associated gripper 1552 a, 1552 b to which thepartially-assembled cartridge is delivered may clamp onto the cartridgesuch that the cartridge may be transported with movement of the indexingtable 1550. In this regard, each gripper 1552 a, 1552 b may includefirst and second opposing portions 1558, 1560 configured to clamp aroundthe base 204 and/or the outer body 216 of each partially-assembledcartridge. Each gripper 1552 a, 1552 b may be actuated in response to arespective component presence sensor 1562 a, 1562 b detecting thepresence of a partially-assembled cartridge at the gripper, and whichhas not been previously determined to be defective as described above.Note that in FIG. 78 the indexing table 1550 is illustrated as rotatedslightly counterclockwise from first angular stop 1554 at which thegrippers 1552 a, 1552 b receive the partially-assembled cartridges fromthe first transfer unit 1504, so as to show the first reject chute 1556.In this regard, the grippers 1552 a, 1552 b are positioned over thereject chute 1556, instead of displaced therefrom, in the first angularstop 1554.

Once received in the grippers 1552 a, 1552 b, the indexing table 1550may index such that the partially-assembled cartridges are transportedto a second angular stop 1564. FIG. 79 illustrates an enlarged view ofthe second angular stop 1564. As illustrated, the second angular stop1564 may include first and second air flow assemblies 1566 a, 1566 b.Each air flow assembly 1566 a, 1566 b includes first and second couplers1568, 1570, one of which engages the base 204 and the other of whichengages an end of the outer body 216 distal to the base. Thereby, eachair flow assembly 1566 a, 1566 b may apply a flow of air through thepartially-assembled cartridge so as to remove any contaminants and/orensure that a pressure drop associated with the partially-assembledcartridge meets specifications.

After the air flow assemblies 1566 release from the partially-assembledcartridges, the indexing table 1550 may index to a third angular stop1572. As illustrated in FIG. 80, the third angular stop 1572 may includea first imaging device 1574 (e.g., a camera) configured to inspect anexterior of the partially-assembled cartridge. In this regard, the firstimaging device 1574 may capture an image of an end of thepartially-assembled cartridge opposite from the base, such that theimage includes the heating element 240, the liquid transport element238, and the reservoir substrate 214 inside the outer body 216. Thereby,a position of one or more of these components may be compared to adesired position thereof. Further, the third angular stop 1572 mayinclude a second imaging device 1576 (e.g., a camera) configured toinspect an exterior of the partially-assembled cartridge. In thisregard, the second imaging device 1576 may capture an image of the sideof the outer body 216 and the base 204 to ensure that the outer body 216is properly crimped to the base and to ensure that the reservoirsubstrate 214 is not exposed at the joint therebetween.

The indexing table 1550 may next index to a fourth angular stop 1578. Asillustrated in FIG. 81, the fourth angular stop 1578 may include firstand second electrical testers 1580 a, 1580 b. The electrical testers1580 a, 1580 b may be configured to ensure that the heating element 240was properly welded to the negative and positive heating terminals 234,235. Further, the electrical testers 1580 a, 1580 b may test thepartially-assembled cartridges to make sure that the control componentterminal 206, the negative heating terminal 234, and the positiveheating terminal 235 are not grounded to the outer body 216. Further, insome embodiments the electrical testers 1580 a, 1580 b may upload codeto the electronic control component 208 which may, for example, controla heating profile dictating how current is directed to the heatingelement 240 when a draw is detected on an associated control body.

The indexing table 1550 may then index to a fifth angular stop 1582. Asillustrated in FIG. 77, the fifth angular stop 1582 may include a secondreject chute 1584. In this regard, when a partially-assembled cartridgefails one of the tests at the second, third, or fourth angular stops1564, 1572, 1578, of the inspection and processing unit 1506, thegripper 1552 a, 1552 b may release the partially-assembled cartridgeover the second reject chute 1584 for disposal, further analysis, orrecycling of the components thereof.

The indexing table 1550 may further index to a sixth angular stop 1586,which corresponds to a position at which the partially-assembledcartridges are proximate the second transfer unit 1508. In this regard,as illustrated in FIG. 73, the second transfer unit 1508 may include arobotic arm 1588 and an end effector 1590. The robotic arm 1588 mayposition the end effector 1590, such that the end effector may grasp apartially-assembled cartridge and transfer the partially-assembledcartridge to an offload conveyor 1592. Thereby, the offload conveyor1592 may transfer the partially-assembled cartridges to the cartridgefilling subsystem 408 for filing, followed by the cartridge cappingsubsystem 412 for capping, and the cartridge labeling subsystem 416 forlabeling (see, FIG. 3).

Note that the inspection subsystem 418 may be distributed across thevarious portions of the system 400 for producing cartridges. In thisregard, by way of example, the inspection subsystem 418 may include thevarious component presence sensors and other sensors configured todetect the position, presence, and other attributes of the components ofthe cartridge as described above.

An assembly method is additionally provided. As illustrated in FIG. 82,the method may include providing a plurality of components via a supplyunit at operation 1602. Further, the method may include alternatinglyfeeding a first portion of the components from the supply unit to afirst assembly unit and a second portion of the components to a secondassembly unit at operation 1604. The method may additionally includeassembling the first portion of the components with the first assemblyunit and the second portion of the components with the second assemblyunit into a plurality of cartridges for an aerosol delivery device atoperation 1606.

In some embodiments, alternatingly feeding the first portion of thecomponents from the supply unit to the first assembly unit and thesecond portion of the components to the second assembly unit atoperation 1604 may include swiveling a rotary member between a firstdelivery position in which the rotary member is configured to deliverthe first portion of the components to the first assembly unit and asecond delivery position in which the rotary member is configured todeliver the second portion of the components to the second assemblyunit. Swiveling the rotary member may include receiving one of thecomponents from the supply unit in a first engagement head while asecond engagement head feeds one of the components to the secondassembly unit and receiving one of the components from the supply unitin the second engagement head while the first engagement head feeds oneof the components to the first assembly unit.

Providing the components via the supply unit at operation 1602 mayinclude directing the components along a pathway in a serially-alignedstream and singulating the components from the serially-aligned stream.The method may additionally include individually removing the componentsfrom the serially-aligned stream or realigning the components whenmisaligned in a first direction. The method may additionally includeremoving the components from the serially-aligned stream through a gapin the pathway when the components are misaligned in a second direction.

An additional embodiment of an assembly method is illustrated in FIG.83. As illustrated, the method may include providing a base and aplurality of additional components collectively configured to form aplurality of cartridges for an aerosol delivery device, the baseextending between an inner end configured to receive the additionalcomponents during assembly of the cartridges and an attachment enddefining an internal surface configured to engage a control body duringusage of the aerosol delivery device at operation 1702. Further, themethod may include providing a plurality of assembly substations, atrack, and a carriage comprising an engagement head defining a pluralityof sections, the track extending between the assembly substations, andthe carriage being configured to engage the track and to cooperatetherewith to move between the assembly substations at operation 1704.The method may further include engaging the internal surface of theattachment end of the base with the sections of the engagement head viaan interference fit to provide the assembly substations with access tothe inner end of the base at operation 1706. The method may also includetransporting the carriage by way of the track between the assemblysubstations at operation 1708. Additionally, the method may includeassembling the additional components with the inner end of the base atthe assembly substations at operation 1710.

Engaging the base with the engagement head at operation 1706 may includerotationally aligning the base with the engagement head. Rotationallyaligning the base with the engagement head comprises detecting arotational orientation of the base based on image of the attachment endof the base. The method may further include storing cartridgeidentification and status information in a storage module coupled to thecarriage. Additionally, the method may include locking the carriage atone or more of the substations by directing one or more locking pinsfrom the track into one or more alignment apertures defined in thecarriage. Transporting the carriage by way of the track at operation1708 may include transporting the carriage by way of a conveyor, andwherein locking the carriage comprises lifting the carriage from theconveyor.

FIG. 84 illustrates an additional assembly method. As illustrated, themethod may include providing a partially-assembled cartridge comprising:a base, a negative heating terminal, a positive heating terminal, aheating element, and a liquid transport element, the negative heatingterminal and the positive heating terminal being coupled to the base,and the heating element being coupled to the negative heating terminaland the positive heating terminal at operation 1802. The method mayadditionally include inserting the partially-assembled cartridge withinan outer body by engaging the outer body with an outer body gripper of arobotic arm and directing the outer body over the partially-assembledcartridge at operation 1804. Further, the method may include applying anegative pressure to the outer body supplied by a suction systemoperably engaged with the outer body gripper of the robotic arm tofacilitate insertion of the partially-assembled cartridge into the outerbody at operation 1806.

In some embodiments the method may further include inserting thepartially-assembled cartridge in a bending mechanism to bend the liquidtransport element against the negative heating terminal and the positiveheating terminal, wrapping a reservoir substrate at least partiallyaround the bending mechanism, and retracting the bending mechanismrelative to the partially-assembled cartridge following wrapping of thereservoir substrate such that the reservoir substrate is wrapped atleast partially about the negative heating terminal and the positiveheating terminal and in contact with the liquid transport element.Applying the negative pressure to the outer body at operation 1806 mayinclude engaging an end of the outer body with a piston of the outerbody gripper, the piston being in fluid communication with the suctionsystem and configured to apply the negative pressure through the outerbody. Further, the method may include pressing the outer body intoengagement with the base with the piston.

As noted above, the system 400 may include a controller 417. Thecontroller 417 may be configured to execute computer code for performingthe operations described herein. As illustrated in FIG. 85, thecontroller 417 may comprise a processor 1902 that may be amicroprocessor or a controller for controlling the overall operationthereof. In one embodiment the processor 1902 may be particularlyconfigured to perform the functions described herein. The controller 417may also include a memory device 204. The memory device 1904 may includenon-transitory and tangible memory that may be, for example, volatileand/or non-volatile memory. The memory device 1904 may be configured tostore information, data, files, applications, instructions or the like.For example, the memory device 1904 could be configured to buffer inputdata for processing by the processor 1902. Additionally oralternatively, the memory device 1904 may be configured to storeinstructions for execution by the processor 1902.

The controller 417 may also include a user interface 1906 that allows auser to interact therewith. For example, the user interface 1906 cantake a variety of forms, such as a button, keypad, dial, touch screen,audio input interface, visual/image capture input interface, input inthe form of sensor data, etc. Still further, the user interface 1906 maybe configured to output information to the user through a display,speaker, or other output device. A communication 1908 interface mayprovide for transmitting and receiving data through, for example, awired or wireless network 1910 such as a local area network (LAN), ametropolitan area network (MAN), and/or a wide area network (WAN), forexample, the Internet.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling the above-describedoperations. In particular, computer readable code may be configured toperform each of the operations of the methods described herein andembodied as computer readable code on a computer readable medium forcontrolling the above-described operations. In this regard, a computerreadable storage medium, as used herein, refers to a non-transitory,physical storage medium (e.g., a volatile or non-volatile memory device,which can be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, CD-ROMs,DVDs, magnetic tape, and optical data storage devices. The computerreadable medium can also be distributed over network-coupled computersystems so that the computer readable code is stored and executed in adistributed fashion.

As noted above, the controller 417 may be configured to execute computercode for performing the above-described operations. In this regard, anembodiment of a non-transitory computer readable medium for storingcomputer instructions executed by a processor in a controller (e.g.controller 417) configured to assemble a cartridge for an aerosoldelivery device is provided. The non-transitory computer readable mediummay comprise program code instructions for providing a plurality ofcomponents via a supply unit; program code instructions foralternatingly feeding a first portion of the components from the supplyunit to a first assembly unit and a second portion of the components toa second assembly unit via a processor; and program code instructionsfor assembling the first portion of the components with the firstassembly unit and the second portion of the components with the secondassembly unit into a plurality of cartridges for an aerosol deliverydevice.

The program code instructions for alternatingly feeding the firstportion of the components from the supply unit to the first assemblyunit and the second portion of the components to the second assemblyunit may include program code instructions for swiveling a rotary memberbetween a first delivery position in which the rotary member isconfigured to deliver the first portion of the components to the firstassembly unit and a second delivery position in which the rotary memberis configured to deliver the second portion of the components to thesecond assembly unit. The program code instructions for swiveling therotary member may include program code instructions for receiving one ofthe components from the supply unit in a first engagement head while asecond engagement head feeds one of the components to the secondassembly unit and receiving one of the components from the supply unitin the second engagement head while the first engagement head feeds oneof the components to the first assembly unit. The program codeinstructions for providing the components via the supply unit mayinclude program code instructions for directing the components along apathway in a serially-aligned stream and singulating the components fromthe serially-aligned stream. The non-transitory computer readable mediummay further comprise program code instructions for individually removingthe components from the serially-aligned stream or realigning thecomponents when misaligned in a first direction. The non-transitorycomputer readable medium may further comprise program code instructionsfor removing the components from the serially-aligned stream through agap in the pathway when the components are misaligned in a seconddirection.

In an additional embodiment, a non-transitory computer readable mediumfor storing computer instructions executed by a processor in acontroller (e.g. controller 417) configured to assemble a cartridge foran aerosol delivery device may comprise program code instructions forproviding a base and a plurality of additional components collectivelyconfigured to form a plurality of cartridges for an aerosol deliverydevice, the base extending between an inner end configured to receivethe additional components during assembly of the cartridges and anattachment end defining an internal surface configured to engage acontrol body during usage of the aerosol delivery device; program codeinstructions for providing a plurality of assembly substations, a track,and a carriage comprising an engagement head defining a plurality ofsections, the track extending between the assembly substations, and thecarriage being configured to engage the track and to cooperate therewithto move between the assembly substations; program code instructions forengaging the internal surface of the attachment end of the base with thesections of the engagement head via an interference fit to provide theassembly substations with access to the inner end of the base; programcode instructions for transporting the carriage by way of the trackbetween the assembly substations; and program code instructions forassembling the additional components with the inner end of the base atthe assembly substations via a processor.

The program code instructions for engaging the base with the engagementhead may comprise program code instructions for rotationally aligningthe base with the engagement head. The program code instructions forrotationally aligning the base with the engagement head may includeprogram code instructions for detecting a rotational orientation of thebase based on image of the attachment end of the base. Thenon-transitory computer readable medium may further comprise programcode instructions for storing cartridge identification and statusinformation in a storage module coupled to the carriage. Thenon-transitory computer readable medium may further comprise programcode instructions for locking the carriage at one or more of thesubstations by directing one or more locking pins from the track intoone or more alignment apertures defined in the carriage. In someembodiments the program code instructions for transporting the carriageby way of the track may include program code instructions fortransporting the carriage by way of a conveyor, and wherein the programcode instructions for locking the carriage may include program codeinstructions for lifting the carriage from the conveyor.

In a further embodiment, a non-transitory computer readable medium forstoring computer instructions executed by a processor in a controller(e.g. controller 417) configured to assemble a cartridge for an aerosoldelivery device may comprise program code instructions for providing apartially-assembled cartridge comprising: a base, a negative heatingterminal, a positive heating terminal, a heating element, and a liquidtransport element, the negative heating terminal and the positiveheating terminal being coupled to the base, and the heating elementbeing coupled to the negative heating terminal and the positive heatingterminal; program code instructions for inserting thepartially-assembled cartridge within an outer body by engaging the outerbody with an outer body gripper of a robotic arm and directing the outerbody over the partially-assembled cartridge; and program codeinstructions for applying a negative pressure to the outer body suppliedby a suction system operably engaged with the outer body gripper of therobotic arm to facilitate insertion of the partially-assembled cartridgeinto the outer body via a processor.

In some embodiments the non-transitory computer readable medium mayfurther comprise program code instructions for inserting thepartially-assembled cartridge in a bending mechanism to bend the liquidtransport element against the negative heating terminal and the positiveheating terminal; program code instructions for wrapping a reservoirsubstrate at least partially around the bending mechanism; and programcode instructions for retracting the bending mechanism relative to thepartially-assembled cartridge following wrapping of the reservoirsubstrate such that the reservoir substrate is wrapped at leastpartially about the negative heating terminal and the positive heatingterminal and in contact with the liquid transport element.

In some embodiments the program code instructions for applying thenegative pressure to the outer body may comprise program codeinstructions for engaging an end of the outer body with a piston of theouter body gripper, the piston being in fluid communication with thesuction system and configured to apply the negative pressure through theouter body. The non-transitory computer readable medium may furthercomprise program code instructions for pressing the outer body intoengagement with the base with the piston.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. A system configured to assemble a pluralityof cartridges for an aerosol delivery device, the system comprising: aplurality of assembly substations collectively configured to assemble abase and a plurality of additional components together, the baseextending between an inner end configured to receive the additionalcomponents during assembly of the cartridges and an attachment enddefining an internal surface configured to engage a control body duringusage of the aerosol delivery device; a track extending between theassembly substations; and a carriage configured to engage the track andto cooperate therewith to move between the assembly substations, thecarriage comprising an engagement head defining a plurality of sectionsconfigured to engage the internal surface of the attachment end of thebase via an interference fit to provide the assembly substations withaccess to the inner end of the base to attach the additional componentsthereto.
 2. The system of claim 1, wherein the assembly substationsinclude a base load substation, the base load substation beingconfigured to rotationally align the base with the engagement head ofthe carriage and engage the base with the engagement head.
 3. The systemof claim 1, wherein the base load substation comprises an imaging deviceconfigured to detect a rotational orientation of the base based on imageof the attachment end of the base.
 4. The system of claim 1, wherein thecarriage comprises a storage module configured to store cartridgeidentification and status information.
 5. The system of claim 1, whereinthe carriage defines one or more alignment apertures and the trackcomprises one or more locking pins configured to engage the alignmentapertures to releasably lock the carriage at one or more of the assemblysubstations.
 6. The system of claim 5, wherein the track furthercomprises a conveyor and a lifter mechanism, the lifter mechanismcomprising the locking pins and being configured to lift the carriagefrom the conveyor.
 7. The system of claim 1, wherein the carriagecomprises an electrostatic dissipative material.
 8. The system of claim7, wherein the carriage further comprises a locator module comprising aferromagnetic material.
 9. An assembly method, comprising: providing abase and a plurality of additional components collectively configured toform a plurality of cartridges for an aerosol delivery device, the baseextending between an inner end configured to receive the additionalcomponents during assembly of the cartridges and an attachment enddefining an internal surface configured to engage a control body duringusage of the aerosol delivery device; providing a plurality of assemblysubstations, a track, and a carriage comprising an engagement headdefining a plurality of sections, the track extending between theassembly substations, and the carriage being configured to engage thetrack and to cooperate therewith to move between the assemblysubstations; engaging the internal surface of the attachment end of thebase with the sections of the engagement head via an interference fit toprovide the assembly substations with access to the inner end of thebase; transporting the carriage by way of the track between the assemblysubstations; and assembling the additional components with the inner endof the base at the assembly substations.
 10. The assembly method ofclaim 9, wherein engaging the base with the engagement head comprisesrotationally aligning the base with the engagement head.
 11. Theassembly method of claim 10, wherein rotationally aligning the base withthe engagement head comprises detecting a rotational orientation of thebase based on image of the attachment end of the base.
 12. The assemblymethod of claim 9, further comprising storing cartridge identificationand status information in a storage module coupled to the carriage. 13.The assembly method of claim 9, further comprising locking the carriageat one or more of the substations by directing one or more locking pinsfrom the track into one or more alignment apertures defined in thecarriage.
 14. The assembly method of claim 13, wherein transporting thecarriage by way of the track comprises transporting the carriage by wayof a conveyor, and wherein locking the carriage comprises lifting thecarriage from the conveyor.